Professional Documents
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Yz125 2022
Yz125 2022
YZ125
Read this manual carefully before operating this vehicle.
YZ125N2
LIT-11626-35-29 B4X-2819U-10 ■
Read this manual carefully
EAM20161
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle
if it is sold.
EAM20080
YZ125N2
OWNER’S SERVICE MANUAL
©2022 by Yamaha Motor Corporation, U.S.A.
First edition, June 2021
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
P/N. LIT-11626-35-29
EAM20180
IMPORTANT
Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s
vast experience in the production of pacesetting racing machines. It represents the highest grade of
craftsmanship and reliability that have made Yamaha a leader.
This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have
any questions about this manual or your machine, please contact your Yamaha dealer.
TIP
• Yamaha continually seeks advancements in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor dis-
crepancies between your machine and this manual. If you have any questions concerning this man-
ual, please consult your Yamaha dealer.
• This manual is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disassem-
bly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical
damage.
EWA20270
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A
SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL
YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPEC-
TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE
THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
EAM30001
2
4
5
6 7
G088877
EAM20083
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9
TUNING 10
GENERAL INFORMATION
IDENTIFICATION ..............................................................................................1-6
2
VEHICLE IDENTIFICATION NUMBER ......................................................1-6
ENGINE SERIAL NUMBER........................................................................1-6
4
VALVE JOINT .............................................................................................1-7
COLLAR (tool for YPVS) ............................................................................1-7
6
CIRCLIPS ...................................................................................................1-9
SPECIAL TOOLS............................................................................................1-12 7
INSTRUMENT AND CONTROL FUNCTIONS ...............................................1-16
8
ENGINE STOP SWITCH ..........................................................................1-16
SHIFT PEDAL...........................................................................................1-16
KICKSTARTER LEVER ............................................................................1-16
FRONT BRAKE LEVER ...........................................................................1-16
REAR BRAKE PEDAL..............................................................................1-16
9
FUEL COCK .............................................................................................1-16
STARTER KNOB (CHOKE)......................................................................1-17
10
FUEL AND ENGINE MIXING OIL.............................................................1-18
STARTING A COLD ENGINE ..................................................................1-18
STARTING A WARM ENGINE .................................................................1-18
BREAK-IN PROCEDURES ......................................................................1-18
MAINTENANCE AFTER BREAK-IN ..............................................................1-20
MAJOR MAINTENANCE ..........................................................................1-20
AIR FILTER MAINTENANCE ...................................................................1-20
TORQUE-CHECK POINTS.............................................................................1-21
EAM20168
ator only. No passengers.
SAFETY INFORMATION 3. The failure of motorists to detect and recog-
Be sure to read this manual carefully and com- nize motorcycles in traffic is the predominat-
pletely in order to operate the machine safely ing cause of automobile/motorcycle
and correctly prior to riding the Yamaha ma- accidents. Many accidents have been
chine, and take care to maintain it properly and caused by an automobile driver who did not
operate it safely. see the motorcycle. Making yourself conspic-
EAM30401
uous appears to be very effective in reducing
FOR SAFETY, BE SURE TO OBEY THE the chance of this type of accident.
FOLLOWING: Therefore:
Be a Responsible Owner • Wear a brightly colored jacket.
As the vehicle’s owner, you are responsible for • Use extra caution when you are approaching
the safe and proper operation of your motorcy- and passing through intersections, since in-
cle. tersections are the most likely places for mo-
Motorcycles are single-track vehicles. torcycle accidents to occur.
Their safe use and operation are dependent • Ride where other motorists can see you.
upon the use of proper riding techniques as well Avoid riding in another motorist’s blind spot.
as the expertise of the operator. Every operator • Never maintain a motorcycle without proper
should know the following requirements before knowledge. Contact an authorized motorcy-
riding this motorcycle. cle dealer to inform you on basic motorcycle
He or she should: maintenance. Certain maintenance can only
1. Obtain thorough instructions from a compe- be carried out by certified staff.
tent source on all aspects of motorcycle oper- 4. Many accidents involve inexperienced opera-
ation. tors.
2. Observe the warnings and maintenance re- • Make sure that you are qualified and that you
quirements in this manual. only lend your motorcycle to other qualified
3. Obtain qualified training in safe and proper operators.
riding techniques. • Know your skills and limits. Staying within
4. Obtain professional technical service as indi- your limits may help you to avoid an accident.
cated in this manual and/or when made nec- • We recommend that you practice riding your
essary by mechanical conditions. motorcycle until you have become thoroughly
5. Never operate a motorcycle without proper familiar with the motorcycle and all of its con-
training or instruction. Take a training course. trols.
Beginners should receive training from a cer- 5. Many accidents have been caused by error of
tified instructor. Contact an authorized motor- the motorcycle operator. A typical error made
cycle dealer to find out about the training by the operator is veering wide on a turn due
courses nearest you. to excessive speed or under cornering (insuf-
Safe Riding ficient lean angle for the speed). Never travel
Perform the pre-operation checks each time you faster than warranted by conditions.
use the vehicle to make sure it is in safe operat- 6. Ride cautiously in unfamiliar areas. You may
ing condition. Failure to inspect or maintain the encounter hidden obstacles that could cause
vehicle properly increases the possibility of an an accident.
accident or equipment damage. Refer to “PRE- 7. The posture of the operator is important for
OPERATION INSPECTION AND MAINTE- proper control. The operator should keep
NANCE” on page 3-4 for a list of pre-operation both hands on the handlebar and both feet on
checks. the operator footrests during operation to
1. This motorcycle is designed for off-road use maintain control of the motorcycle.
only, therefore, it is illegal to operate it on 8. Never ride under the influence of alcohol or
public streets, roads, or highways, even a dirt other drugs.
or gravel one. Off-road use on public lands 9. Be sure the transmission is in neutral before
may be illegal. Please check local regulations starting the engine.
before riding. Protective Apparel
2. This motorcycle is designed to carry the oper- The majority of fatalities from motorcycle acci-
1-1
SAFETY INFORMATION
dents are the result of head injuries. The use of er modifications for Yamaha vehicles. Yamaha
a safety helmet is the single most critical factor is not in a position to test the products that these
in the prevention or reduction of head injuries. aftermarket companies produce. Therefore,
1. Always wear an approved helmet. Yamaha can neither endorse nor recommend
2. Wear a face shield or goggles. Wind in your the use of accessories not sold by Yamaha or
unprotected eyes could contribute to an im- modifications not specifically recommended by
pairment of vision that could delay seeing a Yamaha, even if sold and installed by a Yamaha
hazard. dealer.
3. The use of a jacket, heavy boots, trousers, Aftermarket Parts, Accessories, and Modifi-
gloves, etc., is effective in preventing or re- cations
ducing abrasions or lacerations. While you may find aftermarket products similar
4. Never wear loose-fitting clothes, otherwise in design and quality to genuine Yamaha acces-
they could catch on the control levers, foot- sories, recognize that some aftermarket acces-
rests, or wheels and cause injury or an acci- sories or modifications are not suitable because
dent. of potential safety hazards to you or others. In-
5. Always wear protective clothing that covers stalling aftermarket products or having other
your legs, ankles, and feet. The engine or ex- modifications performed to your vehicle that
haust system become very hot during or after change any of the vehicle’s design or operation
operation and can cause burns. characteristics can put you and others at greater
Avoid Carbon Monoxide Poisoning risk of serious injury or death. You are responsi-
All engine exhaust contains carbon monoxide, a ble for injuries related to changes in the vehicle.
deadly gas. Breathing carbon monoxide can Keep the following guidelines in mind, as well as
cause headaches, dizziness, drowsiness, nau- those provided under “Loading” when mounting
sea, confusion, and eventually death. accessories.
Carbon Monoxide is a colorless, odorless, taste- 1. Never install accessories that would impair
less gas which may be present even if you do the performance of your motorcycle. Careful-
not see or smell any engine exhaust. Deadly lev- ly inspect the accessory before using it to
els of carbon monoxide can collect rapidly and make sure that it does not in any way reduce
you can quickly be overcome and unable to save ground clearance or cornering clearance, lim-
yourself. Also, deadly levels of carbon monoxide it suspension travel, steering travel or control
can linger for hours or days in enclosed or poorly operation.
ventilated areas. If you experience any symp- • Accessories fitted to the handlebar or the
toms of carbon monoxide poisoning, leave the front fork area can create instability due to im-
area immediately, get fresh air, and SEEK MED- proper weight distribution. If accessories are
ICAL TREATMENT. added to the handlebar or front fork area,
1. Do not run engine indoors. Even if you try to they must be as lightweight as possible and
ventilate engine exhaust with fans or open should be kept to a minimum.
windows and doors, carbon monoxide can • Bulky or large accessories may seriously af-
rapidly reach dangerous levels. fect the stability of the motorcycle. Wind may
2. Do not run engine in poorly ventilated or par- attempt to lift the motorcycle, or the motorcy-
tially enclosed areas such as barns, garages, cle may become unstable in cross winds.
or carports. • Certain accessories can displace the opera-
3. Do not run engine outdoors where engine ex- tor from his or her normal riding position. This
haust can be drawn into a building through improper position limits the freedom of move-
openings such as windows and doors. ment of the operator and may limit control
Genuine Yamaha Accessories ability, therefore, such accessories are not
Choosing accessories for your vehicle is an im- recommended.
portant decision. Genuine Yamaha accessories, 2. Use caution when adding electrical accesso-
which are available only from a Yamaha dealer, ries. If electrical accessories exceed the ca-
have been designed, tested, and approved by pacity of the motorcycle’s electrical system,
Yamaha for use on your vehicle. an electric failure could result, which could
Many companies with no connection to Yamaha cause a dangerous loss of lights or engine
manufacture parts and accessories or offer oth- power.
1-2
SAFETY INFORMATION
1-3
LOCATION OF IMPORTANT LABELS
EAM20085
1 2 3, 4
1-4
DESCRIPTION
EAM20086
DESCRIPTION
1 2 3
6 5 4
7 8 9 13 14 15
12 11 10 19 18 17 16
1. Clutch lever 11.Check bolt (Transmission oil level)
2. Engine stop switch 12.Rear brake pedal
3. Front brake lever 13.Valve joint
4. Throttle grip 14.Fuel cock
5. Radiator cap 15.Starter knob
6. Fuel tank cap 16.Drive chain
7. Kickstarter lever 17.Air filter
8. Fuel tank 18.Shift pedal
9. Radiator 19.Front fork
10.Coolant drain bolt
TIP
Designs and specifications of the vehicle are subject to change without notice. Therefore, please note
that the descriptions in this manual may be different from those for the vehicle you have purchased.
1-5
IDENTIFICATION
EAM20087
IDENTIFICATION
There are two significant reasons for knowing
the serial number of your vehicle:
1. When ordering parts, you can give the num-
ber to your Yamaha dealer for positive identi-
fication of the model you own.
2. If your vehicle is stolen, the authorities will
need the number to search for and identify
your vehicle.
EAM30002
EAM30003
1-6
INCLUDED PARTS
EAM20088
INCLUDED PARTS
EAM30372
SIDESTAND
This sidestand “1” is used to support only the
machine when standing or transporting it.
EWA20260
WARNING
• Never apply additional force to the sides-
tand.
• Remove this sidestand before starting out. EAM30615
NOTICE
Be sure to use the collar. If the collar is not
used, the power valve constituent parts will
result in damage.
EAM30005
NIPPLE WRENCH
The nipple wrench “1” is used to tighten the
spoke.
EAM30534
VALVE JOINT
This valve joint “1” prevents fuel from flowing out
and is installed to the fuel tank breather hose.
ECA27110
NOTICE
In this installation, make sure the arrow fac-
es the fuel tank and also downward.
1-7
IMPORTANT INFORMATION
EAM20089
ceive an injury or a burn on the engine, the
IMPORTANT INFORMATION exhaust pipe, the silencer, or the like.
EAM30009
7. If coolant is left adhered to the chassis, paint
PREPARATION FOR REMOVAL AND and plating will be damaged. Therefore, rinse
DISASSEMBLY it out with water in good time.
EWA18970
1. Before the jobs, completely remove mud,
WARNING
dust, and the like in order to prevent the entry
of them into the inside during the jobs. Coolant is potentially harmful and should be
Refer to “CARE” on page 1-23. handled with special care.
• If it enters your eyes, wash it away with wa-
ter enough and then get medical attention
• If it splashes on your skin or clothes, quick-
ly wash it away with water and then with
soapy water.
• If it is swallowed, immediately induce vom-
iting and get medical attention.
EAM30010
REPLACEMENT PARTS
Make sure that the parts and grease or oil to be
2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic
fer to “SPECIAL TOOLS” on page 1-12. replacement parts, are new YAMAHA genuine
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar appear-
ances or because the quality may be changed
by aging.
1-8
IMPORTANT INFORMATION
1. Oil
2. Lip
3. Spring
4. Grease
EAM30012
CIRCLIPS
When assembling parts, always use new cir-
clips. During installation of a circlip, make sure
that the edge “2” of the circlip “1” is positioned
opposite to the force “3” that the circlip receives.
Install the circlip with its end aligned with the
center of the spline, without opening the circlip
more than necessary.
EAM30013
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
1-9
BASIC SERVICE INFORMATION
EAM20120
• There are many types of coupler locks;
BASIC SERVICE INFORMATION therefore, be sure to check the type of cou-
EAM30181
pler lock before disconnecting the coupler.
ELECTRICAL SYSTEM
Checking the electrical system
ECA14371
NOTICE
Never insert the tester probes into the cou-
pler terminal slots. Always insert the probes
from the opposite end “a” of the coupler, tak-
ing care not to loosen or damage the leads.
ECA16790
NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.
ECA16640
NOTICE
For waterproof couplers, never insert the
tester probes directly into the coupler. When
performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
2. Check:
• Lead
• Coupler
• Connector
Moisture Dry with compressed air.
Rust/stains Connect and disconnect sev-
eral times.
NOTICE
• When disconnecting a coupler, release the 3. Check:
coupler lock, hold both sections of the cou- • All connections
pler securely, and then disconnect the cou- Loose connection Connect properly.
pler.
1-10
BASIC SERVICE INFORMATION
TIP
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling or assembling a coupler,
pull on the leads to make sure that they are in-
stalled securely.
5. Check:
• No continuity
Digital circuit tester (CD732)
90890-03243
1 Model 88 Multimeter with tachom-
eter
YU-A1927
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (4).
• As a quick remedy, use a contact revitalizer
available at most part stores.
4. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector,
make sure that both terminals are connected
securely.
• Make sure all connections are tight.
1-11
SPECIAL TOOLS
EAM20121
SPECIAL TOOLS
The following special tools are required for accurate and complete adjustment and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised tech-
niques. The shape and tool number used for the special tool differ by country, so two types are provid-
ed. Refer to the list provided to avoid errors when placing an order.
TIP
• For U.S.A. and Canada, use tool number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use tool number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
1-12
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration
pages
YU-01304
1-13
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration
pages
YU-90058/YU-90059
1-14
SPECIAL TOOLS
YU-24460-A
YU-33984
1-15
INSTRUMENT AND CONTROL FUNCTIONS
EAM20181
EAM30188
1
EAM30185
SHIFT PEDAL
The shift pedal “1” has adopted a method of 1
down & 5 ups (press-down & kick-ups).
Press it down for N (neutral) to 1st, and kick it up
for 2nd to 6th.
EAM30189
EAM30186
KICKSTARTER LEVER
Rotate the kickstarter lever “1” away from the en-
gine. Push the starter down lightly with your foot
until the gears engage, then kick smoothly and
forcefully to start the engine. This model has a
primary kickstarter lever so the engine can be EAM30611
1-16
INSTRUMENT AND CONTROL FUNCTIONS
in this position.
EAM30444
1-17
STARTING AND BREAK-IN
EAM20123
4. Run the engine at idle or slightly higher until it
STARTING AND BREAK-IN warms up: this usually takes about one or two
EAM30538
minutes.
FUEL AND ENGINE MIXING OIL 5. The engine is warmed up when it responds
Mix oil with the gas at the ratio specified below. normally to the throttle with the starter knob
Always use fresh, name-brand gasoline, and (CHOKE) turned off.
EWA19030
mix the oil and gas the day of the race. Do not
WARNING
use premix that is more than a few hours old.
Since exhaust gas contains harmful ingredi-
Recommended fuel ents, do not start or warm it up at an illventi-
Premium unleaded gasoline lated place or a closed narrow place.
(E10 acceptable)
6. To stop the engine, push the engine stop
switch.
TIP
If knocking or pinging occurs, use a different TIP
brand of gasoline or higher octane grade. Continue pushing the engine stop switch till the
engine comes to a full stop.
ECA22260
NOTICE EAM30197
Never mix two types of oil in the same batch; STARTING A WARM ENGINE
clotting of the oil could result. If you wish to Do not operate the starter knob (CHOKE). Open
change oil types, be sure to drain the fuel the throttle slightly and start the engine by kick-
tank and the carburetor float bowl of old pre- ing the kickstarter forcefully with firm stroke.
mix prior to filling with the new type. EAM30198
BREAK-IN PROCEDURES
Fuel tank capacity A break-in is important so that rotating portion,
7.0 L (1.8 US gal, 1.5 Imp.gal) sliding surfaces, and mounted areas may fit one
another, and that the rider may become accus-
Engine oil tomed to the machine.
Lubrication system ECA25811
1-18
STARTING AND BREAK-IN
on.
ECA25821
NOTICE
After a break-in or after each race, always
check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them.
Also when the following parts are replaced, a
break-in is required.
• Cylinder and Crankshaft: A break-in is re-
quired for about an hour.
• Piston, Piston ring, Valve, Camshaft, and
Gear: A break-in is required for about 30
minutes at a throttle opening of 1/2 or less.
Observe the condition of the engine carefully
during a break-in.
For checkpoints for a break-in, see “MAIN-
TENANCE AFTER BREAK-IN”. If any prob-
lem is found, immediately stop the engine
and make a checkup.
1-19
MAINTENANCE AFTER BREAK-IN
EAM20124
• Cable
MAINTENANCE AFTER BREAK-IN Grease and adjust cables.
After a break-in, perform careful maintenance to • Drive chain
get ready for the next practice or race. Lubricate the drive chain and adjust its ten-
Refer to “PRE-OPERATION INSPECTION AND sion.
MAINTENANCE” on page 3-4. • Fuel tank
EAM30199
Clean the inside of the fuel tank and the fuel
MAJOR MAINTENANCE cock. Check for leaks.
1. For the engine • Suspension
• Leaks around the engine Check for oil leaks in the front fork or the rear
Check for pressure leaks from the cylinder shock absorber. Check that the mounted
head or the cylinder, oil leaks from the crank- conditions are good.
case or the case cover, leaks from the cool- • Sprocket
ant system, and other leaks. Check for looseness in the sprocket mounted
• Check that the cylinder, the piston, and the on the rear wheel.
piston ring fit one another, and that contact • Mounting bolts and nuts
between the cylinder and the piston are cor- Check mounted areas for looseness.
ECA25831
rect.
NOTICE
• Transmission oil change
Drain the oil, and check for dirt and foreign After a break-in or before each race, always
materials such as metal chips. (If any foreign check the points shown in “TORQUE-
material is mixed, disassemble and check the CHECK POINTS” for tightening torques and
transmission.) retighten them.
Pour the specified amount of the recom- • Greasing and oiling
mended oil. Always grease or oil the specified points.
• Carburetor
EAM30195
Disassemble the carburetor and clean the AIR FILTER MAINTENANCE
small holes, blowing them with compressed Apply the Yamaha foam air filter oil or other qual-
air. ity foam air filter oil to the element. (Excess oil in
• CDI magneto the element may adversely affect engine start-
Check for looseness in mounted areas of the ing.)
rotor and the stator. Refer to “CLEANING THE AIR FILTER ELE-
Check that the connector is not being discon- MENT” on page 3-8.
nected.
• Silencer
Check the main body and stay for cracks.
Check for leaks.
• Mounting bolts and nuts
Check for looseness in mounted areas of
parts, as well as engine mounting bolts and
engine brackets.
2. For the chassis
• Check welds and mounted areas of the
frame, the swingarm, the link, the bracket,
and so on, for looseness and cracks.
• Wheel(s)
Check the wheel for runout. Check the spoke
for looseness.
• Brake(s)
Check the brake disc mounting bolt for loose-
ness.
Check that the reservoir contains the speci-
fied amount of brake fluid. Check for leaks.
1-20
TORQUE-CHECK POINTS
EAM20125
TORQUE-CHECK POINTS
Frame construction Combined seat and fuel tank Fuel tank to frame
Frame to rear frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Seat Seat to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear Link Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Mounting of rear shock absorber Rear shock absorber and frame
Mounting of swingarm Tightening of pivot shaft
Wheel(s) Mounting of wheel Front Tightening of wheel axle
Tightening of axle holder
Tightening of spoke nipple
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Tightening of spoke nipple
Brake(s) Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel pump to fuel tank
Shift pedal Shift pedal to shift shaft
1-21
TORQUE-CHECK POINTS
TIP
Concerning the tightening torque, refer to “TIGHTENING TORQUES” on page 2-9.
1-22
MOTORCYCLE CARE AND STORAGE
EAM20126
ucts are used on hard-to-remove dirt, do
MOTORCYCLE CARE AND STOR- not leave the cleaner on the affected area
AGE any longer than instructed. Also, thorough-
ly rinse the area off with water, immediately
EAM30200
dry it, and then apply a corrosion protec-
CARE
tion spray.
While the open design of a motorcycle reveals
• Improper cleaning can damage plastic
the attractiveness of the technology, it also
parts (such as cowlings, panels, wind-
makes it more vulnerable. Rust and corrosion
shields, headlight lenses, meter lenses,
can develop even if high-quality components are
etc.) and the mufflers. Use only a soft, clean
used. A rusty exhaust pipe may go unnoticed on
cloth or sponge with water to clean plastic.
a car, however, it detracts from the overall ap-
However, if the plastic parts cannot be thor-
pearance of a motorcycle. Frequent and proper
oughly cleaned with water, diluted mild de-
care does not only comply with the terms of the
tergent with water may be used. Be sure to
warranty, but it will also keep your motorcycle
rinse off any detergent residue using plenty
looking good, extend its life and optimize its per-
of water, as it is harmful to plastic parts.
formance.
• Do not use any harsh chemical products on
Before cleaning
plastic parts. Be sure to avoid using cloths
TIP or sponges which have been in contact
Be sure to confirm that the vehicle is completely
with strong or abrasive cleaning products,
cooled.
solvent or thinner, fuel (gasoline), rust re-
1. Block or cover the following parts with suit- movers or inhibitors, brake fluid, antifreeze
able measures. or electrolyte.
• Air intake port “1” • For motorcycles equipped with a wind-
• Water pump housing hole at the bottom “2” shield: Do not use strong cleaners or hard
• Crankcase cover hole at the bottom (left side) sponges as they will cause dulling or
“3” scratching. Some cleaning compounds for
• Silencer exhaust port “4” plastic may leave scratches on the wind-
• End of each hose shield. Test the product on a small hidden
part of the windshield to make sure that it
1 does not leave any marks. If the windshield
is scratched, use a quality plastic polishing
compound after washing.
4 • When cleaning using either a high-pres-
sure cleaning machine or a water hose, do
not direct the water jet toward the following
areas:(Otherwise, it could cause either
damage due to the water pressure or mal-
3 2
function due to water entry.)
Wheels or swing arm bearings
2. Make sure that all caps and covers as well as
Fork seals or brake seals
all electrical couplers and connectors, includ-
Electrical parts, such as couplers, switch-
ing the spark plug cap, are tightly installed.
es, battery, etc.
3. Remove extremely stubborn dirt, like oil burnt
Muffler or hoses
onto the crankcase, with a degreasing agent
Air cleaner intake port
and a brush, but never apply such products
• Do not clean using a water jet with the seat
onto seals, gaskets, sprockets, the drive
or cover removed.
chain and wheel axles. Always rinse the dirt
and degreaser off with water.
Cleaning
ECA26730
NOTICE
• Avoid using strong acidic wheel cleaners,
especially on spoked wheels. If such prod-
1-23
MOTORCYCLE CARE AND STORAGE
WARNING
Contaminants on the brakes or tires can
cause loss of control.
• Make sure that there is no oil or wax on the
brakes or tires.
After normal use • If necessary, clean the brake discs and
Remove dirt with warm water, a mild detergent, brake linings with a regular brake disc
and a soft, clean sponge, and then rinse thor- cleaner or acetone, and wash the tires with
oughly with clean water. Use a toothbrush or warm water and a mild detergent. Before
bottlebrush for hard-to-reach areas. Stubborn riding at higher speeds, test the motorcy-
dirt and insects will come off more easily if the cle’s braking performance and cornering
area is covered with a wet cloth for a few min- behavior.
utes before cleaning.
ECA24240
After riding in the rain, near the sea or on salt-
NOTICE
sprayed roads
Since sea salt or salt sprayed on roads during • Apply spray oil and wax sparingly and
winter are extremely corrosive in combination make sure to wipe off any excess.
with water, carry out the following steps after • Never apply oil or wax to any rubber and
each ride in the rain, near the sea or on salt- plastic parts, but treat them with a suitable
sprayed roads. care product.
• Avoid using abrasive polishing com-
TIP
Salt sprayed on roads in the winter may remain pounds as they will wear away the paint.
well into spring. TIP
• Consult a Yamaha dealer for advice on what
1. Clean the motorcycle with cold water and a
products to use.
mild detergent, after the engine has cooled
• Washing, rainy weather or humid climates can
down.
cause the headlight lens to fog. Turning the
NOTICE: Do not use warm water since it
headlight on for a short period of time will help
increases the corrosive action of the salt.
remove the moisture from the lens.
2. Apply a corrosion protection spray on all met-
al, including chrome- and nickel-plated, sur-
EAM30201
faces to prevent corrosion. STORAGE
After cleaning Short-term
1. Dry the motorcycle with a chamois or an ab- Always store your motorcycle in a cool, dry place
sorbing cloth. and, if necessary, protect it against dust with a
2. Immediately dry the drive chain and lubricate porous cover. Be sure the engine and the ex-
it to prevent it from rusting. haust system are cool before covering the mo-
3. Use a chrome polish to shine chrome, alumi- torcycle.
num and stainless- steel parts, including the ECA24250
1-24
MOTORCYCLE CARE AND STORAGE
stored.
Long-term
Before storing your motorcycle for several
months:
1. Follow all the instructions in “CARE” on page
1-23.
2. Drain the fuel tank, fuel lines, and the carbu-
retor float bowl.
3. Perform the following steps to protect the cyl-
inder, piston rings, etc. from corrosion.
a. Remove the spark plug, pour a tablespoon
of motor oil in the spark plug hole, and re-
install the plug. With the engine stop
switch pushed in, kick the engine over
several times to coat the cylinder walls
with oil.
4. Lubricate all control cables and the pivoting
points of all levers and pedals as well as of
the sidestand.
5. Check and, if necessary, correct the tire air
pressure, and then lift the motorcycle so that
both of its wheels are off the ground. Alterna-
tively, turn the wheels a little every month in
order to prevent the tires from becoming de-
graded in one spot.
6. Cover the muffler outlet with a plastic bag to
prevent moisture from entering it.
TIP
Make any necessary repairs before storing the
motorcycle.
1-25
MOTORCYCLE CARE AND STORAGE
1-26
SPECIFICATIONS
ENGINE SPECIFICATIONS..............................................................................2-2
1
CHASSIS SPECIFICATIONS............................................................................2-5
ELECTRICAL SPECIFICATIONS.....................................................................2-8
2
TIGHTENING TORQUES..................................................................................2-9
3
GENERAL TIGHTENING TORQUE SPECIFICATIONS ............................2-9
ENGINE TIGHTENING TORQUES ..........................................................2-10
CHASSIS TIGHTENING TORQUES ........................................................2-11
4
5
6
7
8
9
10
GENERAL SPECIFICATIONS
EAM20127
GENERAL SPECIFICATIONS
Model
Model B4X1
B4X5
Dimensions
Overall length 2135 mm (84.1 in)
Overall width 825 mm (32.5 in)
Overall height 1295 mm (51.0 in)
Seat height 980 mm (38.6 in)
Wheelbase 1445 mm (56.9 in)
Ground clearance 365 mm (14.37 in)
Weight
Curb weight 95 kg (209 lb)
Riding capacity 1 person
2-1
ENGINE SPECIFICATIONS
EAM20128
ENGINE SPECIFICATIONS
Engine
Combustion cycle 2-stroke
Cooling system Liquid cooled
Induction system Reed valve
Displacement 125 cm³
Number of cylinders Single cylinder
Bore stroke 54.0 54.5 mm (2.13 2.15 in)
Compression ratio 8.2–10.1 : 1
Starting system Kickstarter
Fuel
Recommended fuel Premium unleaded gasoline (E10 acceptable)
Fuel tank capacity 7.0 L (1.8 US gal, 1.5 Imp.gal)
Engine oil
Recommended brand YAMALUBE
Lubrication system Premix lubrication
Engine oil YAMALUBE 2R
Premix ratio 30
Transmission oil
Type Motor oil SAE 10W-40 type SG or higher
Quantity (disassembled) 0.76 L (0.80 US qt, 0.67 Imp.qt)
Quantity 0.70 L (0.74 US qt, 0.62 Imp.qt)
Cooling system
Coolant quantity
Radiator (including all routes) 0.90 L (0.95 US qt, 0.79 Imp.qt)
Radiator cap valve opening pressure 93.3–122.7 kPa (0.93–1.23 kgf/cm², 13.5–17.8
psi)
Spark plug(s)
Manufacturer/model NGK/BR9EVX
Spark plug gap 0.6–0.7 mm (0.024–0.028 in)
Cylinder head
Warpage limit 0.03 mm (0.0012 in)
Cylinder
Bore 54.000–54.014 mm (2.1260–2.1265 in)
Wear limit 54.064 mm (2.1285 in)
Piston
Piston-to-cylinder clearance 0.040–0.045 mm (0.0016–0.0018 in)
Diameter 53.957–53.972 mm (2.1243–2.1249 in)
Measuring point (from piston skirt bottom) 17.5 mm (0.69 in)
Piston pin bore inside diameter limit 15.040 mm (0.5921 in)
Piston pin outside diameter limit 14.975 mm (0.5896 in)
Piston-pin-to-piston-pin-bore clearance 0.008–0.023 mm (0.0003–0.0009 in)
Piston ring
Top ring
End gap limit 1.20 mm (0.0472 in)
Ring side clearance 0.035–0.070 mm (0.0014–0.0028 in)
Side clearance limit 0.100 mm (0.0039 in)
2-2
ENGINE SPECIFICATIONS
Crankshaft
Crank assembly width 55.90–55.95 mm (2.201–2.203 in)
Runout limit 0.030 mm (0.0012 in)
Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)
Friction plate thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.110 in)
Plate quantity 8 pcs
Clutch plate thickness 1.50–1.70 mm (0.059–0.067 in)
Plate quantity 7 pcs
Warpage limit 0.20 mm (0.008 in)
Clutch spring free length 41.20 mm (1.62 in)
Clutch spring free length limit 39.20 mm (1.54 in)
Push rod bending limit 0.30 mm (0.012 in)
Drivetrain
Primary reduction ratio 3.368 (64/19)
Transmission type Constant mesh 6-speed
Gear ratio
1st 2.385 (31/13)
2nd 1.933 (29/15)
3rd 1.588 (27/17)
4th 1.353 (23/17)
5th 1.176 (20/17)
6th 1.056 (19/18)
Main axle runout limit 0.01 mm (0.0004 in)
Drive axle runout limit 0.01 mm (0.0004 in)
Secondary reduction ratio 3.769 (49/13)
Final drive Chain
Air filter
Air filter element Wet element
Air filter oil grade Yamaha foam air filter oil or other quality foam
air filter oil
Carburetor
Type quantity PWK38S 1
ID mark B4X1 00
Main jet #160
Main air jet #200
Jet needle NYDF-2
Needle jet 2.9(#6)
Cutaway #7
Pilot outlet 0.8
Pilot jet #75
Bypass 1 1.5
Air screw turns out 2-5/8
Valve seat size 3.8
Starter jet 1 #85
Power Jet #35
Float height 6.5 mm (0.26 in)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
2-3
ENGINE SPECIFICATIONS
Reed valve
Thickness 0.400 mm (0.0157 in)
Valve bending limit 0.2 mm (0.01 in)
2-4
CHASSIS SPECIFICATIONS
EAM20129
CHASSIS SPECIFICATIONS
Chassis
Caster angle 26.0
Trail 109 mm (4.3 in)
Front wheel
Wheel type Spoke wheel
Rim size 21 x 1.60
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Rear wheel
Wheel type Spoke wheel
Rim size 19 x 1.85
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Front tire
Type With tube
Size 80/100-21 51M
Manufacturer/model BRIDGESTONE/X20F
Rear tire
Type With tube
Size 100/90-19 57M
Manufacturer/model BRIDGESTONE/X20R
Tire air pressure (measured on cold tires)
Front 100 kPa (1.00 kgf/cm², 15 psi)
Rear 100 kPa (1.00 kgf/cm², 15 psi)
Front brake
Type Hydraulic single disc brake
Brake disc thickness limit 2.5 mm (0.10 in)
Brake disc runout limit (as measured on 0.15 mm (0.0059 in)
wheel)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 9.52 mm (0.37 in)
Caliper cylinder inside diameter (Left) 25.40 mm, 25.40 mm (1.00 in, 1.00 in)
Specified brake fluid DOT 4
Rear brake
Type Hydraulic single disc brake
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on 0.15 mm (0.0059 in)
wheel)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm (1.00 in)
Specified brake fluid DOT 4
Front suspension
Type Telescopic fork
Spring Coil spring
2-5
CHASSIS SPECIFICATIONS
2-6
CHASSIS SPECIFICATIONS
2-7
ELECTRICAL SPECIFICATIONS
EAM20130
ELECTRICAL SPECIFICATIONS
Ignition system
Ignition system CDI
Ignition timing (B.T.D.C.) 0.50 mm (0.02 in)
Pickup coil resistance 248.0–372.0
Charging coil 1 resistance 720.0–1080.0
Charging coil 2 resistance 44.0–66.0
Ignition coil
Primary coil resistance 0.24–0.36
Secondary coil resistance 5.68–8.52 k
Spark plug cap
Resistance 5.00 k
Charging system
Charging system CDI magneto
2-8
TIGHTENING TORQUES
EAM20131
TIGHTENING TORQUES
EAM30205
10 mm 6 mm 6 0.6 4.4
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 41
19 mm 14 mm 85 8.5 63
22 mm 16 mm 130 13.0 96
2-9
TIGHTENING TORQUES
EAM30203
Thread
Item Q’ty Tightening torques Remarks
size
2-10
TIGHTENING TORQUES
Thread
Item Q’ty Tightening torques Remarks
size
Clutch boss nut M16 1 80 N·m (8.0 kgf·m, 59 lb·ft) Use a lock
washer.
Clutch spring bolt M6 5 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Locknut (clutch cable side) M6 1 4.3 N·m (0.43 kgf·m, 3.2 lb·ft)
Use a lock
Drive sprocket nut M18 1 75 N·m (7.5 kgf·m, 55 lb·ft)
washer.
Shift pedal bolt M6 1 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Bearing plate cover screw (shift
M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
cam) LT
Thread
Item Q’ty Tightening torques Remarks
size
2-11
TIGHTENING TORQUES
Thread
Item Q’ty Tightening torques Remarks
size
2-12
TIGHTENING TORQUES
Thread
Item Q’ty Tightening torques Remarks
size
2-13
TIGHTENING TORQUES
Thread
Item Q’ty Tightening torques Remarks
size
Side cover bolt (front side) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Side cover bolt (rear side) M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Seat bolt M6 1 11 N·m (1.1 kgf·m, 8.1 lb·ft)
Number plate bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
TIP
Steering ring nut
1. First, tighten the steering ring nut approximately 38 N·m (3.8 kgf·m, 28 lb·ft) by using the steering nut
wrench, then loosen the steering ring nut one turn.
2. Retighten the steering ring nut 7 N·m (0.7 kgf·m, 5.2 lb·ft).
2-14
CABLE ROUTING DIAGRAM
EAM20152
2-15
CABLE ROUTING DIAGRAM
1. Engine stop switch lead K. Pass the radiator breather hose and YPVS
2. Throttle cable breather hose on the outside of the engine
bracket and then inside of the down tube.
3. Clutch cable Then pass the radiator breather hose inside
4. Ignition coil the YPVS breather hose.
5. High tension cord L. Clamp the CDI magneto lead, radiator
6. Clamp breather hose and YPVS breather hose to
the frame. Do not cut the end of the clamp.
7. Air vent hose Pay attention so that the YPVS breather hose
8. Radiator breather hose is not crushed when installing the clamp.
9. CDI magneto lead M. Clamp the CDI magneto lead and radiator
10.YPVS breather hose breather hose to the rear side of the frame.
11.Cable guide Pay attention so that the radiator breather
hose is not crushed when installing the
12.Frame (weld bead) clamp. Position the end of the clamp inside
13.Sub-lead wire (throttle position sensor the YPVS breather hose. Take care to clamp
lead/solenoid valve lead) them above the projection on the frame. Do
14.Engine bracket (left) not cut the end of the clamp.
15.Crankcase breather hose N. Do not clamp throttle cable and clutch cable.
16.Overflow hose O. Locate the clamp ends in the arrowed range.
17.Rear shock absorber P. 30
Tighten the clamp with its screw head in the
18.Connector cover arrowed range.
A. Align the throttle cable locating tape with the Q. Pass the throttle cable back of the air vent
cable guide. Fasten each part with the plastic hose.
locking tie. R. The position of the air vent hose (right) and
B. From the outside of the vehicle, pass the overflow hose does not matter after passing
engine stop switch lead, clutch cable and the clamp.
throttle cable. S. Pass the air vent hoses, overflow hose and
C. Insert the fuel tank breather hose end into the crankcase breather hose so that they do not
steering shaft hole. contact the rear shock absorber.
D. Pass the throttle cable, clutch cable and T. Position the clip as shown in the illustration.
engine stop switch lead above the radiator Locate the clip in the arrowed range.
hose. U. After connecting the coupler, make sure that
E. Install the ignition coil and side core together the connector cover contacts the end of the
to the frame. coupler.
F. Clamp the throttle cable, high tension cord
and sub-lead wire (throttle position sensor
lead/solenoid valve lead) to the frame. Posi-
tion the lock portion under the frame. After
tightening the clamp, cut off the end of the
clamp so that the remaining end is 1–5 mm
(0.04–0.20 in) in length.
G. Make sure the high tension cord does not
contact with clutch cable. (It does not matter
if the clutch cable contacts with the grom-
met.)
H. Clamp the clutch cable and sub-lead wire
(throttle position sensor lead/solenoid valve
lead) to the engine bracket (left). The lock
portion should face the inner side of the vehi-
cle, while the end should face the rear side of
the vehicle. Make sure the connector cover
does not contact with engine. Do not cut the
end of the clamp.
I. Pass the air vent hose front of the throttle
cable.
J. Pass the air vent hose, overflow hose and
crankcase breather hose between the frame
and connecting rod.
2-16
CABLE ROUTING DIAGRAM
2-17
CABLE ROUTING DIAGRAM
1. High tension cord J. Pass the CDI magneto lead and radiator
2. Clamp breather hose between the frame and the
radiator (right).
3. Ignition coil lead
K. Place the clamp end so that it is located out-
4. CDI unit side the vehicle beyond the ignition coil lead.
5. CDI unit band L. After connecting the coupler, make sure that
6. Sub-lead wire (throttle position sensor the connector cover (throttle position sensor
lead/solenoid valve lead) lead/solenoid valve lead) contacts the end of
7. Joint connector the coupler.
8. Engine stop switch lead M. Clamp the wire harness with two white tapes.
9. Radiator breather hose N. Good
10.CDI magneto lead O. No good
11.Throttle cable P. Pass the throttle cable and clutch cable under
the frame (weld bead).
12.Clutch cable Place the clamp end so that it is located
13.Connector cover under the clutch cable of the vehicle.
14.Frame (weld bead) Q. Insert the CDI unit band until it stops at the
15.CDI unit stay CDI unit stay.
R. Pass the throttle cable, clutch cable and
A. Pass the high tension cord to the left of the engine stop switch lead under the frame
radiator hose. (weld bead).
B. No cable routing such as wire harness on the S. After connecting the couplers, move the han-
push pin of the frame. dlebar all the way to the right side and clamp
C. Clamp the CDI magneto lead and ignition coil the leads without applying too much power.
lead to the frame at its locating tape. After T. Pass the CDI magneto lead and radiator
tightening the clamp, cut off the end of the breather hose between the frame and the
clamp so that the remaining end is 1–5 mm radiator hose so that they come within the
(0.04–0.20 in) in length. The tightening direc- arrow-indicated range. Also take care so that
tion does not matter. the CDI magneto lead passes on the left of
D. Clamp to the frame the ignition coil lead. After the radiator breather hose.
tightening the clamp, cut off the end of the
clamp so that the remaining end is 1–5 mm
(0.04–0.20 in) in length. The tightening direc-
tion does not matter.
E. Clamp to the frame the throttle cable, clutch
cable, ignition coil lead and engine stop
switch lead. In so doing, clamp the ignition
coil lead and engine stop switch lead at their
protecting tubes.
Align the engine stop switch lead with the
positioning tape portion, and then clamp the
lead. The clamp position should be close to
the damper.
After tightening the clamp, cut off the end of
the clamp so that the remaining end is 1–5
mm (0.04–0.20 in) in length. The tightening
direction does not matter.
F. Clamp to the frame the throttle cable, clutch
cable and engine stop switch lead. In so
doing, clamp the engine stop switch lead at
its protecting tube. After tightening the clamp,
cut off the end of the clamp so that the
remaining end is 1–5 mm (0.04–0.20 in) in
length. The tightening direction does not mat-
ter.
G. Pass the radiator breather hose under the
clamp ends.
H. Face the CDI unit coupler projection outside
of the vehicle when installing the CDI unit.
I. Face the joint connector with its open end
downward, and there is no pinching with
peripheral parts. Joint connection position
does not matter.
2-18
CABLE ROUTING DIAGRAM
m
0m )
n
(0 i
m
0m )
n
(0 i
2-19
CABLE ROUTING DIAGRAM
1. Brake hose
2. Master cylinder
3. Engine stop switch lead
4. Engine stop switch
5. Throttle cable
6. Clutch cable
7. Clamp
8. Cable guide
2-20
CABLE ROUTING DIAGRAM
2-21
CABLE ROUTING DIAGRAM
1. Protector
2. Rear brake caliper
3. Bleed screw
4. Gasket
5. Rear brake hose
6. Brake pedal
7. Rear brake master cylinder assembly
8. Spring
9. Frame
2-22
CABLE ROUTING DIAGRAM
2-23
PERIODIC CHECKS AND ADJUSTMENTS
4
CLEANING THE AIR FILTER ELEMENT ...................................................3-8
CHECKING THE CARBURETOR JOINT ...................................................3-9
CHECKING THE CARBURETOR HOSES .................................................3-9
CHECKING THE EXHAUST SYSTEM .....................................................3-10
CHECKING THE COOLANT LEVEL ........................................................3-10
5
CHECKING THE COOLING SYSTEM .....................................................3-11
CHANGING THE COOLANT ....................................................................3-11
CHASSIS ........................................................................................................3-13
6
ADJUSTING THE FRONT DISC BRAKE .................................................3-13
ADJUSTING THE REAR DISC BRAKE ...................................................3-13
CHECKING THE BRAKE FLUID LEVEL ..................................................3-14
CHECKING THE FRONT BRAKE PADS .................................................3-14
CHECKING THE REAR BRAKE PADS....................................................3-14
7
CHECKING THE FRONT BRAKE HOSE .................................................3-14
CHECKING THE REAR BRAKE HOSE ...................................................3-15
CHECKING THE BRAKE OPERATION ...................................................3-15
BLEEDING THE HYDRAULIC BRAKE SYSTEM.....................................3-15
DRIVE CHAIN SLACK ..............................................................................3-16
CHECKING AND ADJUSTING THE STEERING HEAD ..........................3-17
LUBRICATING THE STEERING HEAD ...................................................3-18
CHECKING THE FRONT FORK LEGS....................................................3-18
8
ADJUSTING THE FRONT FORK LEGS ..................................................3-18
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY.....................3-20
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ...................3-20
CHECKING THE SWINGARM OPERATION ...........................................3-22
LUBRICATING THE SWINGARM PIVOT ................................................3-22
9
CHECKING THE CONNECTING ARM AND RELAY ARM ......................3-22
CHECKING THE TIRES ...........................................................................3-23
CHECKING AND TIGHTENING THE SPOKES .......................................3-23
CHECKING THE WHEELS ......................................................................3-23
CHECKING THE WHEEL BEARINGS .....................................................3-23
10
CHECKING THE CHASSIS FASTENERS ...............................................3-23
CHECKING AND LUBRICATING THE CABLES......................................3-24
LUBRICATING THE BRAKE LEVER .......................................................3-24
LUBRICATING THE CLUTCH LEVER .....................................................3-24
LUBRICATING THE PEDAL.....................................................................3-24
ELECTRICAL SYSTEM..................................................................................3-25
CHECKING THE IGNITION TIMING ........................................................3-25
MAINTENANCE INTERVALS
EAM20157
MAINTENANCE INTERVALS
EAM30369
MAINTENANCE INTERVALS
ECA25871
NOTICE
• After a break-in or before each race, always check the points shown in “TORQUE-CHECK
POINTS” for tightening torques and retighten them.
• Periodic inspection is essential in making full use of the machine performance. The life of
parts varies significantly according to the environment in which the machine runs (e.g., rain,
dirt, etc.). Therefore, earlier inspection is required by reference to the list below.
TIP
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
• Replace.
• Replace.
• Replace bearings.
3-1
MAINTENANCE INTERVALS
• Check condition.
• Clean and regap.
15 Spark plug
• Replace.
• Replace.
• Check coolant level and for leak-
age.
• Check hoses for cracks or dam-
17 * Cooling system age.
• Check radiator cap spring opera-
tion.
• Change coolant. Every 2 years
3-2
MAINTENANCE INTERVALS
• Check operation.
• Check throttle grip free play, and
31 * Throttle grip
adjust if necessary.
• Lubricate cable and grip housing.
3-3
PRE-OPERATION INSPECTION AND MAINTENANCE
EAM20134
Coolant Check that coolant is filled up to the radiator cap. Check the 3-10, 3-11, 3-11,
cooling system for leakage. 6-3, 6-3
Check that a fresh gasoline is filled in the fuel tank. Check
Fuel 1-18
the fuel line for leakage.
Check that the oil level is correct. Check the crankcase for
Transmission oil 3-6, 3-6
leakage.
Check that gears can be shifted correctly in order and that
Gear shifter and clutch 3-7, 3-8
the clutch operates smoothly.
Check that the throttle grip operation and free play are cor-
Throttle grip/Housing rectly adjusted. Lubricate the throttle grip and housing, if 3-5, 3-24
necessary.
3-13, 3-13, 3-14,
Check the play of front brake and effect of front and rear
Brakes 3-14, 3-14, 3-14,
brake.
3-15, 3-15
Check drive chain slack and alignment. Check that the
Drive chain 3-16, 4-65, 4-65
drive chain is lubricated properly.
Check for excessive wear and tire pressure. Check for 3-23, 3-23, 3-23,
Wheels
loose spokes and have no excessive play. 3-23
Check that the handlebar can be turned smoothly and have
Steering 3-17
no excessive play.
Front forks and rear Check that they operate smoothly and there is no oil leak- 3-18, 3-18, 3-20,
shock absorber age. 3-20, 3-22
Check that the clutch and throttle cables move smoothly.
Cables (wires) Check that they are not caught when the handlebars are —
turned or when the front forks travel up and down.
Check that the exhaust pipe is tightly mounted and has no
Exhaust pipe 3-10
cracks.
Check that the rear wheel sprocket tightening bolt is not 4-8, 4-8, 4-8, 4-8,
Rear wheel sprocket
loose. 4-9, 4-9
3-24, 3-24, 3-24,
Lubrication Check for smooth operation. Lubricate if necessary. 3-24
Bolts and nuts Check the chassis and engine for loose bolts and nuts. 1-21
Check that the stator coil assembly, CDI and ignition coil
Lead connectors are connected tightly. 1-10
Is the machine set suitably for the condition of the racing 10-9, 10-9, 10-9,
course and weather or by taking into account the results of 10-10, 10-10, 10-11,
Settings
test runs before racing? Are inspection and maintenance 10-11, 10-12, 10-12,
completely done? 10-14, 10-15
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple setting
adjustments may only be left, in order to get enough time to use effectively.
3-4
ENGINE
EAM20135
gine idling speed should be adjusted.
ENGINE
1. Check:
EAM30607 • Throttle grip free play “a”
ADJUSTING THE PILOT AIR SCREW Out of specification Regulate.
1. Adjust:
• Pilot air screw “1” Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)
TIP G088895
To optimize the fuel flow at a smaller throttle
opening, each vehicle’s pilot air screw has been 2. Adjust:
individually set at the factory. Before adjusting • Throttle grip free play
the pilot air screw, turn it in fully and count the a. Slide the adjuster cover.
number of turns. Record this number as the fac- b. Loosen the locknut “1”.
tory-set number of turns out. c. Turn the adjuster “2” until the specified
free play is obtained.
a. Turn in the pilot air screw until it is lightly d. Tighten the locknut.
seated. EWA18470
EAM30254
3-5
ENGINE
G088879
7. Install:
• Spark plug
Spark plug
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
TIP
Before installing the spark plug, clean the spark
plug and gasket surface. EAM30540
3-6
ENGINE
G088887
2. Adjust:
• Clutch lever free play
Handlebar side
a. Turn the adjuster “1” until the specified
clutch lever free play is obtained.
5. Drain:
• Transmission oil
6. Install:
• Aluminum washer New
• Oil drain bolt
Oil drain bolt
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
7. Fill: TIP
• Transmission oil If the clutch lever free play cannot be obtained
on the handlebar side, use the adjuster on the
Type clutch cable side.
Motor oil SAE 10W-40 type SG or
higher Clutch cable side
Quantity (disassembled) a. Slide the clutch cable cover.
0.76 L (0.80 US qt, 0.67 Imp.qt) b. Loosen the locknut “1”.
Quantity c. Turn the adjuster “2” until the specified
0.70 L (0.74 US qt, 0.62 Imp.qt) clutch lever free play is obtained.
d. Tighten the locknut “1”.
8. Check:
• Oil leakage Locknut (clutch cable side)
9. Check: 4.3 N·m (0.43 kgf·m, 3.2 lb·ft)
T.
R.
3-7
ENGINE
EAM30370
3. Wash:
ADJUSTING THE CLUTCH LEVER POSITION • Air filter element
1. Adjust: a. After washing the element with air filter
• Clutch lever position “a” cleaner or kerosene, squeeze and dry it
Loosen the locknut “1” and use the adjuster completely.
EWA19110
“2” to adjust the clutch lever position “a” as WARNING
desired.
Do not use gasoline or organic (acid/alka-
line) volatile oil for washing.
ECA24280
NOTICE
Do not twist the element when squeezing the
element.
4. Check:
• Air filter element
Damage Replace.
5. Apply:
2. Tighten: Yamaha foam air filter oil or other quality
• Locknut foam air filter oil.
a. Put the air filter element into a plastic bag
Locknut (clutch lever position) and drip the filter oil into the bag.
5 N·m (0.5 kgf·m, 3.7 lb·ft) b. With the element inside the bag, rub it
T.
R.
3-8
ENGINE
1
b
ECA26420
6. Install: NOTICE
• Air filter guide “1”
Make sure that the air filter element is prop-
TIP erly seated in the air filter case. The engine
Align the projection “a” on filter guide with the should never be operated without the air fil-
hole “b” in air filter element. ter element installed, otherwise the piston(s)
and/or cylinder(s) may become excessively
worn.
EAM30541
1
7. Apply:
• Lithium-soap-based grease
(on the matching surface “a” on air filter case)
EAM30542
TIP
Align the projection “a” on filter guide with the 1
hole “b” in air filter case. 1
3-9
ENGINE
EAM30221
T.
• Silencer fiber LOCTITE®
R.
a. Remove the silencer bolts “1”, silencer “2” Silencer bolt “2”
and fiber bolts “3”. 12 N·m (1.2 kgf·m, 8.9 lb·ft)
TIP Side cover bolt (front side)
Remove the inner pipe while holding the silencer 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Side cover bolt (rear side)
in place with a vise etc.
9 N·m (0.9 kgf·m, 6.6 lb·ft)
3
3 2 1
1
3
1
b. Remove the inner pipe “1”.
c. Replace the fiber “2”. EAM30210
3-10
ENGINE
Crack/damage Replace.
Refer to “RADIATOR” on page 6-2.
3. Install:
• Air scoop (left/right)
• Seat
• Side cover (left/right)
Refer to “GENERAL CHASSIS” on page 4-1.
EAM30212
3. Check: WARNING
• Coolant level A hot radiator is under pressure. Therefore,
Maximum level “a” or below Add coolant do not remove the radiator cap when the en-
up to the maximum level. gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.
3-11
ENGINE
6. Pour coolant.
Recommended coolant
High quality ethylene glycol
anti-freeze containing anti-cor-
rosion for aluminum engine
Radiator (including all routes)
0.90 L (0.95 US qt, 0.79 Imp.qt)
Coolant mixing ratio
1:1 (Coolant:Water)
EWA13040
WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
• If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA13481
NOTICE
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.
7. Install:
• Radiator cap
8. Start the engine, warm this up for several
minutes, stop it, and then wait for it to cool
down.
9. Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-10.
3-12
CHASSIS
EAM20136
air must be removed by bleeding the brake
CHASSIS system. Air in the brake system will consid-
EAM30479
erably reduce braking performance.
ADJUSTING THE FRONT DISC BRAKE ECA13490
TIP NOTICE
There should be no free play at the brake lever After adjusting the brake lever position,
end. make sure there is no brake drag.
1. Check: 4. Install:
• Brake lever position “a” • Brake lever cover
Brake lever position EAM30480
WARNING
a Adjust the pedal height between the maxi-
mum “A” and the minimum “B” as shown. (In
this adjustment, the bolt “3” end “a” should
protrude out of the lower adjusting nut “4”
but not be less than 2.0 mm (0.08 in) “b”
G088889
away from the brake pedal “5”).
2. Remove:
• Brake lever cover
3. Adjust:
• Brake lever position
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” until the speci- 2
fied brake lever position is obtained.
1
2
1 A B
3 3
4
a b
c. Tighten the locknut.
Locknut (front brake lever posi- 5
tion)
c. Tighten the locknut to specification.
T.
EWA13050
Rear brake pedal adjusting lock-
WARNING nut
T.
3-13
CHASSIS
EWA19150 ECA13540
WARNING NOTICE
A soft or spongy feeling in the brake pedal Brake fluid may damage painted surfaces
can indicate the presence of air in the brake and plastic parts. Therefore, always clean up
system. Before running, bleed the brake sys- any spilt brake fluid immediately.
tem. Air in the brake system will cause brak-
ing performance to be reduced. EAM30231
ECA13510
CHECKING THE FRONT BRAKE PADS
NOTICE The following procedure applies to all of the
brake pads.
After adjusting the brake pedal position,
1. Operate the brake.
make sure there is no brake drag.
2. Check:
EAM30234
• Front brake pad
CHECKING THE BRAKE FLUID LEVEL Wear indicator grooves “1” almost touch the
1. Stand the vehicle upright on a level surface. brake disc Replace the brake pads as a
TIP set.
In order to ensure a correct reading of the brake Refer to “FRONT BRAKE” on page 4-11.
fluid level, make sure that the top of the brake
fluid reservoir is horizontal.
2. Check:
• Brake fluid level
The minimum level mark “a” or below Add.
Specified brake fluid 1
DOT 4
EAM30232
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to 1
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance. EAM30478
• When refilling, be careful that water does CHECKING THE FRONT BRAKE HOSE
not enter the brake fluid reservoir. Water 1. Check:
will significantly lower the boiling point of • Brake hose
the brake fluid and could cause vapor lock. Cracks/damage/wear Replace.
3-14
CHASSIS
WARNING
A. Front
Bleed the brake system whenever: B. Rear
• The system is disassembled.
• A brake hose is loosened, disconnected, or d. Slowly apply the brake several times.
replaced. e. Fully pull the brake lever or fully press
• The brake fluid level is very low. down the brake pedal and hold it in posi-
• Brake operation is faulty. tion.
f. Loosen the bleed screw.
1. Remove:
TIP
• Brake master cylinder cap
Loosening the bleed screw will release the pres-
• Reservoir diaphragm
sure in the brake caliper and cause the brake le-
3-15
CHASSIS
ver to contact the throttle grip or the brake pedal N (5.0 kgf, 37 lbf).
to fully extend. 4. Check:
• Drive chain slack “a”
g. Tighten the bleed screw and then release
Out of specification Regulate.
the brake lever or brake pedal.
h. Repeat steps (d) to (g) until all of the air TIP
Measure drive chain slack between the drive
bubbles have disappeared from the brake
chain guide and the bottom of the chain as
fluid in the plastic hose.
shown.
TIP
During the procedure, keep adding brake fluid to
the reservoir.
ECA24320
NOTICE
• Wipe off any brake fluid on the brake discs,
tires, wheels, etc.
• Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
i. Tighten the bleed screw.
Drive chain slack (Maintenance
Brake caliper bleed screw
Stand)
6 N·m (0.6 kgf·m, 4.4 lb·ft)
48.0–58.0 mm (1.89–2.28 in)
T.
R.
WARNING TIP
Securely support the vehicle so that there is • To maintain the proper wheel alignment, adjust
no danger of it falling over. both sides evenly.
• Push the rear wheel forward to make sure that
2. Shift the transmission into the neutral posi- there is no clearance between the swingarm
tion. end plates and the ends of the swingarm.
3. Pull the drive chain up above the drive chain
guide installation bolt with a force of about 50 d. Tighten the wheel axle nut.
3-16
CHASSIS
EAM30247
2
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Use a maintenance stand to raise the front
Steering nut wrench
wheel off the ground.
EWA13120
90890-01403
WARNING Exhaust flange nut wrench
YU-A9472
Securely support the vehicle so that there is
no danger of it falling over.
Steering ring nut (initial tighten-
2. Check: ing torque)
• Steering head
T.
38 N·m (3.8 kgf·m, 28 lb·ft)
R.
Grasp the bottom of the front fork legs and
gently rock the front fork. c. Turn the front fork to the right and left a few
Blinding/looseness Adjust the steering times, and make sure that the steering ro-
head. tates smoothly. If it does not turn smooth-
3. Remove: ly, remove the lower bracket and check
• Handlebar the upper and lower bearings.
Refer to “HANDLEBAR” on page 4-33. Refer to “STEERING HEAD” on page
• Upper bracket 4-51.
Refer to “STEERING HEAD” on page 4-51. d. Loosen the ring nut fully turn and then
4. Adjust: tighten it to specification with a steering
• Steering head nut wrench.
a. Remove the washer “1”. EWA21110
WARNING
3-17
CHASSIS
a
5. Install:
• Upper bracket
6. Remove:
Refer to “STEERING HEAD” on page 4-51.
• Protector
• Handlebar
• Dust seal “1”
Refer to “HANDLEBAR” on page 4-33. ECA24330
EAM30502
NOTICE
LUBRICATING THE STEERING HEAD Be careful not to damage the dust seal and
1. Lubricate: the inner tube by a driver.
• Upper bearing
• Lower bearing
• Bearing race
Recommended lubricant
Lithium-soap-based grease
EAM30338
WARNING
Securely support the vehicle so that there is 7. Clean:
no danger of it falling over. • Dust seal “a”
• Oil seal “b”
2. Check:
• Inner tube TIP
• Clean the dust seal and oil seal after every run.
Damage/scratches Replace.
• Apply lithium-soap-based grease on the inner
• Front fork leg
tube.
Oil leaks between inner tube and outer tube
Replace the oil seal.
3. Hold the vehicle upright and apply the front
brake.
4. Check: a
• Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds b
smoothly. LS
Unsmooth operation Correct or replace.
Refer to “FRONT FORK” on page 4-39.
5. Check: EAM30239
• Protector guide “1” ADJUSTING THE FRONT FORK LEGS
Out of specification Replace. EWA19180
TIP WARNING
The protector guide reaches the limit of its use • Always adjust the left and right front forks
when it is worn down to the same height “a” as evenly. If this is not done, the vehicle may
3-18
CHASSIS
3-19
CHASSIS
WARNING WARNING
Securely support the vehicle so that there is Securely support the vehicle so that there is
no danger of it falling over. no danger of it falling over.
2. Remove the bleed screw “1” and release the Spring preload
internal pressure from the front fork. ECA24360
3. Tighten: NOTICE
• Bleed screw Do not turn the adjuster forcibly beyond its
adjusting range.
Bleed screw (front fork)
1.3 N·m (0.13 kgf·m, 0.95 lb·ft) 1. Remove:
• Rear frame
T.
R.
EAM30482
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
d. Turn the adjuster in the direction of “b” or
• Rear shock absorber assembly
“c” to make an adjustment.
Gas leaks/oil leaks Replace the rear shock
absorber assembly. Direction “b”
Refer to “REAR SHOCK ABSORBER AS- Spring preload is increased (suspen-
SEMBLY” on page 4-55. sion is harder).
3. Check: Direction “c”
• Rear shock absorber assembly smooth ac- Spring preload is decreased (suspen-
tion sion is softer).
• Rear suspension link smooth action
Sit astride the seat and shake your body up
and down several times to check whether the
rear shock absorber assembly operates
smoothly.
Unsmooth operation Correct or replace.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-55.
EAM30242
3-20
CHASSIS
b c
NOTICE 1. Adjust:
• Compression damping (for fast compression
Do not turn the adjuster forcibly beyond its
damping)
adjusting range.
a. Turn the adjuster “1” in the direction of “a”
1. Adjust: or “b” to make an adjustment.
• Rebound damping
a. Turn the adjuster “1” in the direction of “a” Direction “a”
or “b” to make an adjustment. Compression damping is increased
(suspension is harder).
Direction “a” Direction “b”
Rebound damping is increased (sus- Compression damping is decreased
pension is harder). (suspension is softer).
Direction “b”
Rebound damping is decreased (sus-
pension is softer).
3-21
CHASSIS
NOTICE EAM30240
Do not turn the adjuster forcibly beyond its CHECKING THE SWINGARM OPERATION
adjusting range. 1. Check:
• Swingarm smooth action
1. Adjust:
• Swingarm free play
• Compression damping (for slow compression
Refer to “SWINGARM” on page 4-60.
damping)
a. Turn the adjuster “1” in the direction of “a” EAM30500
3-22
CHASSIS
EAM30243
loose spoke will sound flat.
CHECKING THE TIRES
1. Measure: 2. Tighten:
• Tire pressure • Spoke
Out of specification Regulate. (with a spoke nipple wrench “1”)
TIP
• Check the tire while it is cold.
G089060
• Because if the bead stopper tightening nut is
loose when the tire pressure is low, the tire
Spoke nipple wrench (6–7)
could slip off the rim, thus be sure to check and 90890-01521
tighten the bead stopper tightening nut “a”. Spoke nipple wrench (6–7)
• If the tire valve stem “b” is found tilted, the tire YM-01521
is considered to be slipping off its position. Cor-
rect the tire position.
Nipple (spoke)
T.
R. 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
TIP
• Do not give a half turn (180) or more for one
a tightening.
• Make sure that tightening after a break-in is
b
done until the initial looseness in nipples disap-
pears.
• Make sure that tightening is done in stages, not
at a time.
a. Bead stopper tightening nut EAM30245
WARNING
Bend/damage Replace.
Loose Tighten. Never attempt to make any repairs to the
Tap the spokes with a screwdriver. wheel.
EAM30246
3-23
CHASSIS
WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:
• Outer cable
Damage Replace.
2. Check:
• Cable operation
Rough movement Lubricate.
Recommended lubricant
Engine oil or a suitable cable lu-
bricant
TIP
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
EAM30483
EAM30503
EAM30250
3-24
ELECTRICAL SYSTEM
EAM20137
Punch mark “a” on rotor should be aligned
ELECTRICAL SYSTEM with punch mark “b” on stator.
EAM30255
Not aligned Adjust.
CHECKING THE IGNITION TIMING
1. Remove:
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
• Spark plug
• Crankcase cover (left)
2. Attach:
• Dial gauge “1”
• Spark plug hole dial stand “2”
Dial gauge & stand set
90890-01252 7. Adjust:
Dial gauge set • Ignition timing
YU-03097-B a. Loosen the stator coil screws “1”.
b. Align the punch mark on the rotor with
punch mark on the stator by moving the
stator “2”.
c. Tighten the stator coil screws.
Stator coil screw
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
6. Check:
• Ignition timing
3-25
ELECTRICAL SYSTEM
3-26
CHASSIS
GENERAL CHASSIS........................................................................................4-1
REMOVING THE NUMBER PLATE ...........................................................4-2
REMOVING THE SIDE COVER .................................................................4-2
2
DISASSEMBLING THE FRONT WHEEL ...................................................4-4
CHECKING THE FRONT WHEEL .............................................................4-4
ASSEMBLING THE FRONT WHEEL .........................................................4-4
INSTALLING THE FRONT WHEEL ...........................................................4-5
4
CHECKING AND REPLACING THE REAR WHEEL SPROCKET.............4-8
ASSEMBLING THE REAR WHEEL ...........................................................4-9
INSTALLING THE REAR WHEEL ..............................................................4-9
6
DISASSEMBLING THE FRONT BRAKE CALIPER .................................4-17
CHECKING THE FRONT BRAKE CALIPER............................................4-17
ASSEMBLING THE FRONT BRAKE CALIPER .......................................4-17
INSTALLING THE FRONT BRAKE CALIPER..........................................4-18
REMOVING THE FRONT BRAKE MASTER CYLINDER ........................4-19
7
CHECKING THE FRONT BRAKE MASTER CYLINDER .........................4-19
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER.....................4-19
INSTALLING THE FRONT BRAKE MASTER CYLINDER .......................4-20
8
REAR BRAKE ................................................................................................4-22
INTRODUCTION ......................................................................................4-26
CHECKING THE REAR BRAKE DISC .....................................................4-26
REPLACING THE REAR BRAKE PADS ..................................................4-26
REMOVING THE REAR BRAKE CALIPER .............................................4-28
9
DISASSEMBLING THE REAR BRAKE CALIPER....................................4-28
CHECKING THE REAR BRAKE CALIPER ..............................................4-28
ASSEMBLING THE REAR BRAKE CALIPER..........................................4-29
INSTALLING THE REAR BRAKE CALIPER ............................................4-29
REMOVING THE REAR BRAKE MASTER CYLINDER...........................4-30
10
CHECKING THE REAR BRAKE MASTER CYLINDER ...........................4-30
ASSEMBLING THE REAR BRAKE MASTER CYLINDER .......................4-30
INSTALLING THE REAR BRAKE MASTER CYLINDER .........................4-31
HANDLEBAR..................................................................................................4-33
REMOVING THE HANDLEBAR ...............................................................4-34
CHECKING THE HANDLEBAR................................................................4-34
INSTALLING THE HANDLEBAR..............................................................4-34
FRONT FORK.................................................................................................4-39
REMOVING THE FRONT FORK LEGS ...................................................4-41
DISASSEMBLING THE FRONT FORK LEGS .........................................4-41
CHECKING THE FRONT FORK LEGS....................................................4-42
ASSEMBLING THE FRONT FORK LEGS ...............................................4-43
INSTALLING THE FRONT FORK LEGS..................................................4-49
STEERING HEAD...........................................................................................4-51
REMOVING THE LOWER BRACKET ......................................................4-52
CHECKING THE STEERING HEAD ........................................................4-52
INSTALLING THE STEERING HEAD ......................................................4-52
SWINGARM ....................................................................................................4-60
REMOVING THE SWINGARM .................................................................4-61
CHECKING THE SWINGARM .................................................................4-61
INSTALLING THE SWINGARM ...............................................................4-61
EAM20094
GENERAL CHASSIS
Removing the seat and side cover
11 N・m (1.1 kgf・m, 8.1 lb・ft)
1
2
4
4-1
GENERAL CHASSIS
EAM30371
EAM30459
4-2
FRONT WHEEL
EAM20095
FRONT WHEEL
Removing the front wheel
21 N・m (2.1 kgf・m, 15 lb・ft)
6
7 2
5
105 N・m (10.5 kgf・m, 77 lb・ft)
8
5
4
(6) 7
6
4-3
FRONT WHEEL
EAM30017
Refer to “CHECKING AND TIGHTENING
REMOVING THE FRONT WHEEL THE SPOKES” on page 3-23.
1. Use a maintenance stand to raise the front 4. Tighten:
wheel off the ground. • Spoke
EWA13120
T.
R.
• Front wheel
TIP
EAM30019 After tightening the spokes, measure the wheel
DISASSEMBLING THE FRONT WHEEL runout.
1. Remove:
• Oil seal 5. Measure:
• Bearing • Radial wheel runout “1”
a. Clean the outside of the front wheel hub. • Lateral wheel runout “2”
b. Remove the oil seals “1” with a flat-head Out of specification Repair/replace.
screwdriver.
TIP 2
To prevent damaging the wheel, place a rag “2”
1
between the screwdriver and the wheel surface.
G088897
1
Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
G088896 2.0 mm (0.08 in)
c. Remove the bearings with a bearing pull-
6. Check:
er.
• Collar
EAM30018 Damage/wear Replace.
CHECKING THE FRONT WHEEL 7. Check:
1. Check: • Bearing
• Front wheel axle Front wheel turns roughly or is loose Re-
Roll the front wheel axle on a flat surface. place the wheel bearings.
Bends Replace. • Oil seal
Damage/wear Replace.
EWA13460
WARNING
Do not attempt to straighten a bent wheel ax- EAM30020
4-4
FRONT WHEEL
LS 1
LS
1
4 EAM30617
2. Install:
• Front wheel axle “1”
TIP
Apply the lithium-soap-based grease to the front
G088898
wheel axle.
2. Install:
• Brake disc
• Front brake disc bolt
Front brake disc bolt
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
LOCTITE®
R.
4-5
FRONT WHEEL
3. Tighten:
• Front wheel axle nut “1”
Front wheel axle nut
105 N·m (10.5 kgf·m, 77 lb·ft)
T.
R.
ECA24430
NOTICE
Before tightening the front wheel axle nut,
push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
4. Tighten:
• Front wheel axle pinch bolt “1”
Front wheel axle pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
4-6
REAR WHEEL
EAM20096
REAR WHEEL
Removing the rear wheel
1 12 N・m (1.2 kgf・m, 8.9 lb・ft)
125 N・m (12.5 kgf・m, 92 lb・ft)
(6)
10
19 N・m (1.9 kgf・m, 14 lb・ft) 7
3 8
9
5
(6)
(6)
5
3
9
7 2
4
4-7
REAR WHEEL
EAM30022
Refer to “CHECKING THE TIRES” on page
REMOVING THE REAR WHEEL 3-23 and “CHECKING THE WHEELS” on
1. Use a maintenance stand to raise the rear page 3-23.
wheel off the ground. 3. Check:
EWA13120
WARNING • Spoke
Refer to “CHECKING AND TIGHTENING
Securely support the vehicle so that there is
THE SPOKES” on page 3-23.
no danger of it falling over.
4. Measure:
2. Remove: • Radial wheel runout
• Rear wheel axle nut “1” • Lateral wheel runout
3. Loosen: Refer to “CHECKING THE FRONT WHEEL”
• Locknut “2” on page 4-4.
4. Tighten:
• Adjusting bolt “3” Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)
EAM30025
2
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
3 1. Check:
• Rear wheel sprocket
1 More than 1/4 tooth wear “a” Replace the
rear wheel sprocket and the drive sprocket as
5. Remove: a set.
• Rear wheel axle Bent tooth Replace the rear wheel sprock-
• Rear wheel et and the drive sprocket as a set.
TIP
• Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
• Do not depress the brake pedal with the rear
wheel removed.
EAM30024
Damage/wear Replace.
4-8
REAR WHEEL
TIP
Tighten the self-locking nuts in stages and in a
crisscross pattern.
EAM30026
T.
LOCTITE®
R.
• Right side of bearing shall be installed first.
• Install the oil seal with its manufacture’s marks
or numbers facing outward. TIP
Tighten the bolts in stages and in a crisscross
ECA24440
pattern.
NOTICE
Install the bearing by pressing its outer race 3. Install:
parallel. • Collar “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip.
5
2
1 1
EAM30027
NOTICE
Do not contact the wheel bearing inner race
“1” or balls “2”. Contact should be made
only with the outer race “3”.
TIP
Use a socket “4” that matches the diameter of
the bearing outer race and that of the oil seal.
4-9
REAR WHEEL
2
2 2
3 1
2. Install: 5. Adjust:
• Drive chain “1” • Drive chain slack “a”
TIP
Push the rear wheel “2” forward and install the Drive chain slack (Maintenance
Stand)
drive chain.
48.0–58.0 mm (1.89–2.28 in)
3. Install:
• Drive chain puller (left) “1”
• Rear wheel axle “2”
TIP 6. Tighten:
• Install the drive chain puller (left), and insert the • Rear wheel axle nut “1”
rear wheel axle from the left side. Rear wheel axle nut
• Apply the lithium-soap-based grease to the 125 N·m (12.5 kgf·m, 92 lb·ft)
rear wheel axle.
T.
R.
• Locknut “2”
Drive chain puller locknut
19 N·m (1.9 kgf·m, 14 lb·ft)
T.
R.
1
2
1
2
4. Install:
• Drive chain puller (right) “1”
• Washer “2”
• Rear wheel axle nut “3”
TIP
Temporarily tighten the rear wheel axle nut at
this point.
4-10
FRONT BRAKE
EAM20097
FRONT BRAKE
Removing the front brake caliper
2
8
5
10 4
7
17 N・m (1.7 kgf・m, 13 lb・ft)
6 2.5 N・m (0.25 kgf・m, 1.8 lb・ft)
4-11
FRONT BRAKE
.
S
4-12
FRONT BRAKE
8
6
6 N・m (0.6 kgf・m, 4.4 lb・ft)
7
6 N・m (0.6 kgf・m, 4.4 lb・ft)
9
1
2 4
4-13
FRONT BRAKE
1 New
BF
4-14
FRONT BRAKE
EAM30028
b. Remove the brake caliper.
INTRODUCTION c. Hold the dial gauge at a right angle against
EWA19210
4-15
FRONT BRAKE
T.
R.
d. Install the brake pads “3” and the pad pin.
TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.
2. Measure:
• Brake pad wear limit “a” b a
Out of specification Replace the brake
pads as a set.
Brake pad lining thickness limit
1.0 mm (0.04 in)
3. Install:
• Brake pad
4
a. Connect the plastic hose “1” to the bleed
screw “2” and place a container under the
end of the plastic hose.
2 5
WARNING
Do not reuse the drained brake fluid.
c. Tighten the bleed screw. 6
4-16
FRONT BRAKE
4. Check:
• Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-14.
5. Check:
• Brake lever operation
A softy or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-15.
EAM30030 b. Remove the brake caliper piston dust seal
REMOVING THE FRONT BRAKE CALIPER and the brake caliper piston seal.
TIP
Before disassembling the brake caliper, drain EAM30032
2
1 1
2
EWA19220
WARNING
a. Blow compressed air into the brake hose When the brake caliper is disassembled, re-
joint opening to force out the piston from place the brake caliper piston seal and the
the brake caliper. brake caliper piston dust seal with new ones.
EWA13550
WARNING 2. Check:
• Cover the brake caliper piston with a rag. • Brake caliper bracket
Be careful not to get injured when the pis- Crack/damage Replace.
ton is expelled from the brake caliper. EAM30033
• Never try to pry out the brake caliper pis- ASSEMBLING THE FRONT BRAKE CALIPER
ton. EWA19230
WARNING
• Before installation, clean and lubricate the
internal parts. Use new brake fluid for
4-17
FRONT BRAKE
T.
R.
to swell and distort. Refer to “CHECKING THE FRONT BRAKE
• When the brake caliper is disassembled, re- PADS” on page 3-14.
place the brake caliper piston seal and the 3. Tighten:
brake caliper piston dust seal with new • Front brake hose holder bolt “1”
ones.
Front brake hose holder bolt
Specified brake fluid 9 N·m (0.9 kgf·m, 6.6 lb·ft)
T.
DOT 4
R.
TIP
EAM30035 Make sure that the brake hose holder “2” is in-
INSTALLING THE FRONT BRAKE CALIPER stalled with its upper end “a” aligned with the
1. Install: paint “b” on the brake hose.
• Front brake caliper bracket
• Front brake caliper 2
(temporarily)
• Copper washer New
• Brake hose b
• Union bolt
Front brake caliper bolt
28 N·m (2.8 kgf·m, 21 lb·ft) a
T.
NOTICE EWA13090
2. Install: NOTICE
• Front brake caliper Brake fluid may damage painted surfaces
• Brake pad spring and plastic parts. Therefore, always clean up
• Brake pad any spilt brake fluid immediately.
• Brake pad pin
• Brake hose holder 5. Bleed:
• Brake system
4-18
FRONT BRAKE
7. Check: WARNING
• Brake lever operation • Before installation, all internal brake com-
A softy or spongy feeling Bleed the brake ponents should be cleaned and lubricated
system. with clean or new brake fluid.
Refer to “BLEEDING THE HYDRAULIC • Never use solvents on internal brake com-
BRAKE SYSTEM” on page 3-15. ponents.
EAM30036
EAM30037
1 2
1
3
2
3. Install:
2. Check: • Spring “1”
• Brake master cylinder reservoir cap (to the brake master cylinder piston “2”)
Damage/scratches/wear Replace.
4-19
FRONT BRAKE
TIP • First, tighten the upper bolt, then the lower bolt.
Install the spring with a smaller inside diameter
to the brake master cylinder piston.
2. Install:
• Copper washer “1” New
4. Install: • Brake hose “2”
• Brake master cylinder piston assembly “1” • Union bolt “3”
• Washer “2”
• Circlip “3” Front brake hose union bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
• Dust boot “4”
T.
R.
• Push rod “5” EWA13531
TIP WARNING
• Always install new brake master cylinder kit Proper brake hose routing is essential to in-
“6”. sure safe vehicle operation.
• Before installation, apply brake fluid to the ECA24470
components of the brake master cylinder pis- NOTICE
ton assembly.
During installation, bring the brake hose into
• Before installation, apply silicone grease to the
contact with the brake master cylinder pro-
push rod end.
jection “a” and make its bent portion “b”
• Before installation, apply brake fluid to the in-
face downward.
side of the brake master cylinder.
TIP
Turn the handlebar toward right and left to make
6 New sure that the brake hose does not touch other
parts (e.g., wire harness, cables, leads). Adjust
1
if necessary.
a
2 3 4 5
b
EAM30039 2
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install: 1 3
• Brake master cylinder “1”
3. Pour brake fluid to the brake master cylinder
Front brake master cylinder hold-
reservoir up to the specified level.
er bolt
T.
4-20
FRONT BRAKE
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-15.
5. Check:
• Brake fluid level
The minimum level mark or below Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-14.
6. Check:
• Brake lever operation
A softy or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-15.
4-21
REAR BRAKE
EAM20098
REAR BRAKE
Removing the rear brake caliper
10 N・m (1.0 kgf・m, 7.4 lb・ft) 2.5 N・m (0.25 kgf・m, 1.8 lb・ft)
17 N・m (1.7 kgf・m, 13 lb・ft)
14 3
4
11
15
12
6
S
5
7
10
9
7 N・m (0.7 kgf・m, 5.2 lb・ft)
4-22
REAR BRAKE
1
3
2
4-23
REAR BRAKE
7
1
8
9
2
3
10
5
4
4-24
REAR BRAKE
4-25
REAR BRAKE
EAM30040
EAM30041
b. Loosen the pad pin “3”.
CHECKING THE REAR BRAKE DISC
c. Remove the rear wheel “4” and the brake
1. Check:
caliper “5”.
• Brake disc
Refer to “REAR WHEEL” on page 4-7.
Damage/galling Replace.
2. Measure: 3
• Brake disc thickness
Measure the brake disc thickness at a few dif- 4
ferent locations.
Out of specification Replace.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-15. 5
Brake disc thickness limit
3.5 mm (0.14 in)
4-26
REAR BRAKE
T.
R.
7 d. Install the brake pad “3” and the pad pin
“4”.
TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.
2. Measure: 4
• Brake pad wear limit “a”
Out of specification Replace the brake
pads as a set. 3
Brake pad lining thickness limit
1.0 mm (0.04 in) a
b
3. Install: 7
• Brake pad
a. Connect the plastic hose “1” to the bleed 6
screw “2” and place a container under the
end of the plastic hose.
WARNING
Do not reuse the drained brake fluid.
c. Tighten the bleed screw.
4-27
REAR BRAKE
4. Check:
• Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-14.
5. Check:
• Brake pedal operation
A softy or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC b. Remove the brake caliper piston dust seal
BRAKE SYSTEM” on page 3-15. and the brake caliper piston seal.
EAM30042
EAM30044
REMOVING THE REAR BRAKE CALIPER CHECKING THE REAR BRAKE CALIPER
TIP 1. Check:
Before disassembling the brake caliper, drain • Brake caliper piston “1”
the brake fluid from the entire brake system. Rust/scratches/wear Replace the brake
1. Remove: caliper piston.
• Union bolt • Brake caliper cylinder “2”
• Copper washer Scratches/wear Replace the brake caliper
• Brake hose assembly.
TIP • Brake caliper body “3”
Put the end of the brake hose into a container Cracks/damage Replace the brake caliper
and pump out the brake fluid. assembly.
• Brake fluid delivery passages
EAM30043 (brake caliper body)
DISASSEMBLING THE REAR BRAKE Obstruction Blow out with compressed air.
CALIPER
1. Remove: 2
• Brake caliper piston “1”
• Brake caliper piston seal kit “2” 1
3
1
EWA19270
2
WARNING
When the brake caliper is disassembled, re-
place the brake caliper piston seal and the
a. Blow compressed air into the brake hose brake caliper piston dust seal with new ones.
joint opening to force out the piston from
4-28
REAR BRAKE
2. Check:
• Brake caliper bracket
Crack/damage Replace.
EAM30045
WARNING
• Before installation, clean and lubricate the a
internal parts. Use new brake fluid for b
cleaning and lubricating.
• Never use solvents on internal brake com- 3. Install:
ponents as they will cause the piston seals • Brake pad spring
to swell and distort. • Brake pad
• When the brake caliper is disassembled, re- • Brake pad pin
place the brake caliper piston seal and the • Brake pad pin plug
brake caliper piston dust seal with new
ones. Brake pad pin
17 N·m (1.7 kgf·m, 13 lb·ft)
T.
Brake pad pin plug
R.
Specified brake fluid
DOT 4 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
4-29
REAR BRAKE
WARNING
EAM30048
REMOVING THE REAR BRAKE MASTER • Before installation, all internal brake com-
CYLINDER ponents should be cleaned and lubricated
TIP with clean or new brake fluid.
Before removing the rear brake master cylinder, • Never use solvents on internal brake com-
drain the brake fluid from the entire brake sys- ponents.
tem.
Specified brake fluid
1. Remove: DOT 4
• Union bolt
• Copper washer 1. Wash the brake master cylinder and the
• Brake hose brake master cylinder kit with brake fluid.
TIP 2. Install:
To drain any remaining brake fluid, place a con- • Primary cylinder cup “1”
tainer under the master cylinder and the end of • Secondary cylinder cup “2”
the brake hose. (to the brake master cylinder piston “3”)
EWA19300
EAM30049 WARNING
CHECKING THE REAR BRAKE MASTER Apply brake fluid to the cylinder cups and in-
CYLINDER stall them as shown. Wrong orientation in in-
1. Check: stallation causes poor braking performance.
• Brake master cylinder “1”
Damage/scratches/wear Replace.
• Brake fluid delivery passages “2” 2
(brake master cylinder body)
Obstruction Blow out with compressed air.
1
1 2
2
1
2. Check:
• Brake master cylinder kit
Damage/wear Replace. 3
3. Check:
• Master cylinder reservoir cap
Crack/damage Replace.
4-30
REAR BRAKE
3. Install: EWA13531
1 2
a
4. Install:
• Brake master cylinder piston assembly “1”
• Push rod “2”
• Circlip “3” 2. Pour brake fluid to the brake fluid reservoir up
• Dust boot “4” to the specified level.
TIP
• Always install new brake master cylinder kit Specified brake fluid
DOT 4
“5”.
• Before installation, apply brake fluid to the EWA13090
NOTICE
EAM30051 Brake fluid may damage painted surfaces
INSTALLING THE REAR BRAKE MASTER and plastic parts. Therefore, always clean up
CYLINDER any spilt brake fluid immediately.
1. Install:
• Copper washer New 3. Bleed:
• Brake hose • Brake system
• Union bolt Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-15.
Rear brake hose union bolt 4. Check:
30 N·m (3.0 kgf·m, 22 lb·ft) • Brake fluid level
T.
4-31
REAR BRAKE
4-32
HANDLEBAR
EAM20099
HANDLEBAR
Removing the handlebar
2
4
3
9 N・m (0.9 kgf・m, 6.6 lb・ft)
5
28 N・m (2.8 kgf・m, 21 lb・ft)
6
5 N・m (0.5 kgf・m, 3.7 lb・ft)
11 0.5 N・m (0.05 kgf・m, 0.37 lb・ft)
1
3.8 N・m (0.38 kgf・m, 2.8 lb・ft) 9
13 12 10
7 8
4-33
HANDLEBAR
EAM30052 EWA13120
WARNING
no danger of it falling over.
Securely support the vehicle so that there is 2. Install:
no danger of it falling over. • Lower handlebar holder “1”
• Washer “2”
2. Remove: • Lower handlebar holder nut “3”
• Grip “1”
TIP
TIP • Install the lower handlebar holders with them
Blow in compressed air between the handlebar side having the greater distance “a” from the
or tube guide and the grip. Then remove the grip mounting bolt center facing forward.
which has become loose. • Apply the lithium-soap-based grease on the
thread of the lower handlebar holders.
1 • Installing the lower handlebar holders in the re-
verse direction allow the front-to-rear offset
amount of the handlebar position to be
changed.
• Do not tighten the nuts yet.
G088916
3. Remove:
• Throttle cable housing “1”
• Throttle grip “2”
2
TIP
While removing the throttle cable housing, pull 3
back the rubber cover “3”.
2 1 3
EAM30053
3. Install:
CHECKING THE HANDLEBAR
• Handlebar “1”
1. Check:
• Upper handlebar holder “2”
• Handlebar
• Upper handlebar holder bolt “3”
Bends/cracks/damage Replace.
Upper handlebar holder bolt
EWA13690
WARNING
28 N·m (2.8 kgf·m, 21 lb·ft)
Do not attempt to straighten a bent handle-
T.
R.
4-34
HANDLEBAR
T.
R.
the mark on the handlebar as shown.
• First tighten the bolts on the front side of the
upper handlebar holder, and then tighten the
bolts on the rear side.
5. Install:
• Left grip “1”
Apply the adhesive to the handlebar “2”.
TIP
• Before applying the adhesive, wipe off grease
or oil on the handlebar surface “a” with a lac-
quer thinner.
• Install the left grip to the handlebar so that the
line “b” between the two arrow marks faces
straight upward.
6. Install:
• Engine stop switch “1”
Engine stop switch screw
0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
T.
R.
• Clamp “4”
TIP
4. Tighten: • The engine stop switch, clutch lever holder and
• Lower handlebar holder nut “1” clamp should be installed according to the di-
mensions shown.
4-35
HANDLEBAR
0 mm
(0 in)
0 mm
(0 in)
10.Install:
• Grip cap (upper) “1”
7. Install: • Grip cap (lower) “2”
• Clutch cable “1” • Grip cap bolt “3”
TIP TIP
Apply the lithium-soap-based grease on the Temporarily tighten the grip cap bolts.
clutch cable end.
11.Install:
8. Adjust: • Collar “1”
• Clutch lever free play • Grip cap cover “2”
Refer to “ADJUSTING THE CLUTCH LEVER • Throttle grip “3”
FREE PLAY” on page 3-7. TIP
9. Install: • Apply the lithium-soap-based grease on the
• Right grip “1” throttle grip sliding surface.
Apply the adhesive on the tube guide “2”. • Tighten the grip cap bolts temporarily without
TIP the throttle being fixed to the handlebar.
• Before applying the adhesive, wipe off grease
or oil on the tube guide surface “a” with a lac-
quer thinner.
• Align the mating mark “b” on the right grip with
the slot “c” in the tube guide.
4-36
HANDLEBAR
T.
R.
1 3
12.Install:
• Throttle cable “1”
(to the tube guide “2”)
TIP 15.Adjust:
Apply the lithium-soap-based grease on the
• Throttle grip free play
throttle cable end and tube guide cable winding
Refer to “CHECKING THE THROTTLE
portion.
GRIP” on page 3-5.
16.Install:
1 • Cap cover “1”
13.Install:
• Roller “1”
• Collar “2” 17.Install:
TIP • Brake master cylinder “1”
• Apply the lithium-soap-based grease on the • Brake master cylinder holder “2”
roller sliding surface and cable guide. • Front brake master cylinder holder bolt “3”
• Install the roller so that the “UPPER” mark “a” Front brake master cylinder hold-
faces upward. er bolt
• Pass the throttle cable in the groove “b” in the
T.
roller.
TIP
2 1 • Install the holder so that the arrow mark “a” fac-
es upward.
• First tighten the bolt on the upper side of the
brake master cylinder holder, and then tighten
b the bolt on the lower side.
14.Install:
• Throttle cable cap “1”
• Throttle cable cap screw “2”
4-37
HANDLEBAR
18.Install:
• Grip cap bolt “1”
Grip cap bolt
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
EWA21080
WARNING
After tightening the bolts, check that the
throttle grip “2” moves smoothly. If it does
not, retighten the bolts for adjustment.
4-38
FRONT FORK
EAM20100
FRONT FORK
Removing the front fork legs
3
21 N・m (2.1 kgf・m, 15 lb・ft)
4-39
FRONT FORK
14
5
4
7
15
13
2
9
10
8 3
1
11
12 29 N・m (2.9 kgf・m, 21 lb・ft)
55 N・m (5.5 kgf・m, 41 lb・ft)
1.3 N・m (0.13 kgf・m, 0.95 lb・ft)
4-40
FRONT FORK
EAM30055
• Hold the locknut and remove the adjuster.
REMOVING THE FRONT FORK LEGS
1. Use a maintenance stand to raise the front
ECA24520
NOTICE
wheel off the ground.
EWA13120 Do not remove the locknut as the damper rod
WARNING may go into the damper assembly and not be
Securely support the vehicle so that there is taken out.
no danger of it falling over.
Cap bolt ring wrench
TIP 90890-01501
Record the adjusting screw setting position be- Cap bolt ring wrench
fore loosening the adjuster and the base valve. YM-01501
2. Loosen:
• Upper bracket pinch bolt
• Damper assembly
• Lower bracket pinch bolt
EWA20350
1
WARNING
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg. 4
3
TIP
Before removing the front fork leg from the vehi- 2
cle, loosen the damper assembly “1” with the
cap bolt ring wrench “2”. 3. Remove:
• Dust seal “1”
Cap bolt ring wrench • Stopper ring “2”
90890-01501 (with a flat-head screwdriver)
Cap bolt ring wrench ECA14180
YM-01501 NOTICE
Do not scratch the inner tube.
1 2
1
2
G088920
3. Remove: 4. Remove:
• Front fork leg • Inner tube “1”
EAM30056
a. Push in slowly “a” the inner tube just be-
DISASSEMBLING THE FRONT FORK LEGS fore it bottoms out and then pull it back
1. Drain: quickly “b”.
• Fork oil b. Repeat this step until the inner tube can be
2. Remove: pulled out from the outer tube.
• Adjuster “1”
(from the inner tube)
TIP
• While compressing the inner tube “2”, set the
cap bolt ring wrench “4” between the inner tube
and locknut “3”.
4-41
FRONT FORK
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Check:
• Outer tube
Scratches/wear/damage Replace.
3. Measure:
• Fork spring free length “a”
5. Remove: Out of specification Replace.
• Base valve “1”
(from the damper assembly) Fork spring free length limit
TIP 492.0 mm (19.37 in)
Hold the damper assembly with the cap bolt ring
wrench “2” and use the cap bolt wrench “3” to re-
move the base valve.
YM-01501 4. Check:
• Damper assembly “1”
3 Bend/damage Replace.
• O-ring “2”
2 Wear/damage Replace.
ECA14200
1 NOTICE
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
• When disassembling and assembling the
EAM30057
front fork leg, do not allow any foreign ma-
CHECKING THE FRONT FORK LEGS terial to enter the front fork.
1. Check:
• Inner tube surface
Scratches Repair or replace.
Use #1000 grit wet sandpaper.
Damaged oil lock piece Replace. 1
• Inner tube bends
2
Out of specification Replace.
Use the dial gauge.
Inner tube bending limit
0.2 mm (0.01 in)
5. Check:
TIP • Base valve “1”
The bending value is shown by one half of the Wear/damage Replace.
4-42
FRONT FORK
1
2 1
EAM30058 4. Measure:
ASSEMBLING THE FRONT FORK LEGS • Oil level (left and right) “a”
EWA13660
Out of specification Regulate.
WARNING
• Make sure the oil levels in both front fork
legs are equal.
4-43
FRONT FORK
7. Install:
• Base valve “1”
(to the damper assembly “2”)
TIP
First bring the damper rod pressure to a maxi-
mum. Then install the base valve while releasing
the damper rod pressure.
5. Tighten:
• Locknut “1”
TIP 8. Check:
Fully finger tighten the locknut onto the damper • Damper assembly
assembly. Not fully stretched Repeat the steps (1) to
(7).
9. Tighten:
• Base valve “1”
Base valve (front fork)
29 N·m (2.9 kgf·m, 21 lb·ft)
T.
R.
TIP
Hold the damper assembly with the cap bolt ring
wrench “2” and use the cap bolt wrench “3” to
tighten the base valve.
6. Loosen:
• Compression damping force adjuster “1” Cap bolt wrench
TIP 90890-01500
• Before loosening the damping force adjuster, Cap bolt wrench
record the setting position. YM-01500
Cap bolt ring wrench
• Unless the damping force adjuster is fully loos-
90890-01501
ened, correct damping characteristic cannot be Cap bolt ring wrench
obtained after installation. YM-01501
4-44
FRONT FORK
3 a
2
1
NOTICE
Make sure that the numbered side of the oil
seal faces bottom side.
TIP
1 • Apply the lithium-soap-based grease on the
dust seal lip and oil seal lip.
• Apply the fork oil on the inner tube.
• When installing the oil seal, use vinyl seat with
fork oil applied to protect the oil seal lip.
12.Allow the overflowing oil to escape at the hole
“a” in the damper assembly.
TIP
The overflow measures about 10 cm³ (0.34
US oz, 0.35 Imp.oz).
LS
4-45
FRONT FORK
1
G088922 G088923
15.Install: 18.Install:
• Piston metal “1” New • Oil seal “1” New
TIP TIP
Install the piston metal onto the slot on inner Using a fork seal driver “2”, press the oil seal in
tube. until the stopper ring groove fully appears.
16.Install: 1
• Outer tube “1”
(to the inner tube “2”)
G088924
19.Install:
• Stopper ring “1”
TIP
Fit the stopper ring correctly in the groove in the
outer tube.
17.Install: 1
• Slide metal “1” New
• Washer “2”
(to the outer tube)
TIP
Press the slide metal into the outer tube with fork G088925
seal driver “3”.
20.Install:
Fork seal driver • Dust seal “1” New
90890-01502 TIP
Fork seal driver (48) Apply lithium-soap-based grease on the inner
YM-A0948 tube.
4-46
FRONT FORK
1 2
3 a
21.Check: 24.Install:
• Inner tube smooth movement • Damper assembly “1”
Tightness/binding/rough spots Repeat the (to the inner tube “2”)
steps (14) to (20). ECA24560
NOTICE
Allow the damper assembly to slide slowly
down the inner tube until it contacts the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.
1
22.Measure:
• Distance “a”
Out of specification Turn the locknut to
specification.
2
Distance “a”
16 mm (0.63 in) or more 25.Loosen:
Between the damper assembly • Rebound damping force adjuster “1”
“1” bottom and locknut “2” bot- TIP
tom. • Before loosening the damping force adjuster,
record the setting position.
• Unless the damping force adjuster is fully loos-
ened, correct damping characteristic cannot be
obtained after installation.
1
2
1 a
23.Install:
• Upper spring seat “1”
• Fork spring “2”
(to the damper assembly “3”)
26.Install:
TIP
Install the upper spring seat with its larger dia. • Damper adjusting rod “1”
end “a” facing the fork spring. • Copper washer “2” New
• Adjuster “3”
4-47
FRONT FORK
29.Install:
• Adjuster “1”
(to the inner tube)
Adjuster
55 N·m (5.5 kgf·m, 41 lb·ft)
T.
LOCTITE®
R.
27.Measure: 1
• Gap “a” between the adjuster “1” and the
locknut “2”
Out of specification Retighten and readjust
the locknut.
Gap “a” between the adjuster and
the locknut
0.5–1.0 mm (0.02–0.04 in) 30.Fill:
• Front fork leg
TIP
If it is installed with a gap out of specification, Recommended oil
correct damping force cannot be obtained. Yamaha Suspension Oil S1
Standard oil amount
305 cm³ (10.3 US oz, 10.8 Imp.oz)
1 Extent of adjustment
280–365 cm³ (9.5–12.3 US oz,
9.9–12.9 Imp.oz)
a
ECA24570
NOTICE
• Be sure to use the recommended oil. Other
2
oils may have an adverse effect on front
fork performance.
• When disassembling and assembling the
28.Tighten: front fork leg, do not allow any foreign ma-
• Adjuster (damper assembly) “1” terial to enter the front fork.
Adjuster (damper assembly)
29 N·m (2.9 kgf·m, 21 lb·ft)
T.
R.
4-48
FRONT FORK
31.Install: 2. Tighten:
• Damper assembly “1” • Damper assembly “1”
(to the outer tube)
Damper assembly (front fork)
TIP
30 N·m (3.0 kgf·m, 22 lb·ft)
Temporarily tighten the damper assembly.
T.
R.
TIP
Use the cap bolt ring wrench “2” to tighten the
damper assembly.
1
32.Install:
• Protector guide “1”
3. Adjust:
• Front fork top end “a”
Front fork top end (standard) “a”
EAM30059
5 mm (0.2 in)
INSTALLING THE FRONT FORK LEGS
1. Install:
• Front fork “1” a
TIP
• Temporarily tighten the lower bracket pinch
bolts.
• Do not tighten the upper bracket pinch bolts
yet.
4. Tighten:
• Upper bracket pinch bolt “1”
4-49
FRONT FORK
EWA19320
WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause the 7. Adjust:
front fork to malfunction. • Compression damping force
TIP
Turn in the damping adjuster “1” finger-tight and
then turn out to the originally set position.
5. Install:
• Protector “1”
• Front fork protector bolt “2”
Front fork protector bolt
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
2
6. Adjust:
• Rebound damping force
TIP
Turn in the damping adjuster “1” finger-tight and
then turn out to the originally set position.
4-50
STEERING HEAD
EAM20101
STEERING HEAD
Removing the lower bracket
6
5
7
8
10
1 9
4-51
STEERING HEAD
EAM30060 ECA14270
WARNING TIP
Securely support the vehicle so that there is Always replace the bearing and the bearing race
no danger of it falling over. as a set.
2. Remove:
• Ring nut “1”
TIP
Remove the ring nut with the steering nut
wrench “2”.
EWA13730
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
G088934
4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage Replace.
EAM30061 EAM30062
4-52
STEERING HEAD
3. Install:
• Lower bracket “1”
TIP
Apply the lithium-soap-based grease on the
bearing, the portion “a” and thread of the steer-
ing stem.
LS 6. Install:
• Washer “1”
a
LS
4. Install:
• Steering ring nut “1”
Steering ring nut
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
7. Install:
R.
4-53
STEERING HEAD
T.
R.
• Lower bracket pinch bolt “2”
Lower bracket pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
EWA19330
WARNING
Tighten the lower bracket to specified
8. Install: torque. If torqued too much, it may cause the
• Steering stem nut “1” front fork to malfunction.
Steering stem nut
145 N·m (14.5 kgf·m, 107 lb·ft)
T.
R.
TIP
Apply the lithium-soap-based grease to the con-
tact surface of the steering stem nut when in-
stalling.
11.Tighten:
• Upper bracket pinch bolt “1”
4-54
REAR SHOCK ABSORBER ASSEMBLY
EAM20102
4
12 14
5 6
7
10
9
1 2
8
12 11
11 32 N・m (3.2 kgf・m, 24 lb・ft)
12 3
13 29 N・m (2.9 kgf・m, 21 lb・ft)
53 N・m (5.3 kgf・m, 39 lb・ft)
2.3 N・m (0.23 kgf・m, 1.7 lb・ft)
4-55
REAR SHOCK ABSORBER ASSEMBLY
5 5
6
6
4 5
4
5 3
6
1 6
5
5
4
80 N・m (8.0 kgf・m, 59 lb・ft)
3
4 3
6
6
2
4-56
REAR SHOCK ABSORBER ASSEMBLY
EAM30063 EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
This rear shock absorber contains highly
compressed nitrogen gas. Before handling 2. Remove:
the rear shock absorber, read and make sure • Rear shock absorber assembly lower bolt “1”
you understand the following information. TIP
The manufacturer cannot be held responsi- While removing the rear shock absorber assem-
ble for property damage or personal injury bly lower bolt, hold the swingarm so that it does
that may result from improper handling of not drop down.
the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor- 1
mance.
3. Remove:
TIP • Rear shock absorber assembly upper bolt
A break-in is required up to about 50 km of run- • Rear shock absorber assembly
ning.
EAM30067
4-57
REAR SHOCK ABSORBER ASSEMBLY
NOTICE
Do not apply the grease to the bearing outer
a
race because it will wear the rear shock ab-
sorber surface on which the bearing is press
fitted.
2. Lubricate:
1 • O-ring
2
2 4 Recommended lubricant
Lithium-soap-based grease
3
3 3. Install:
• Bearing
1 1 • Stopper ring New
(into the rear shock absorber assembly (up-
3 per side))
3
TIP
2 5 • Install the bearing parallel until the stopper ring
2 groove appears by pressing its outer race.
• After installing the stopper ring, push back the
bearing until it contacts the stopper ring.
3. Install: 4. Install:
• Bearing “1” • Bearing “1”
• Oil seal “2” New • Bushing “2”
(into the connecting arm “3”) • Collar “3”
• Collar “4” • Dust seal “4” New
(into the rear shock absorber assembly (low-
er side))
4-58
REAR SHOCK ABSORBER ASSEMBLY
TIP
Install the dust seals with their lips facing inward. Connecting arm nut (relay arm
side)
T.
80 N·m (8.0 kgf·m, 59 lb·ft)
R.
Installed depth “a”
4.25 mm (0.17 in) • Relay arm nut (swingarm side)
Relay arm nut (swingarm side)
70 N·m (7.0 kgf·m, 52 lb·ft)
T.
R.
• Rear shock absorber assembly lower nut
Rear shock absorber assembly
lower nut
T.
53 N·m (5.3 kgf·m, 39 lb·ft)
R.
8. Install:
• Rear frame “1”
5. Lubricate: • Rear frame bolt (upper) “2”
• Connecting arm and frame bolt
Rear frame bolt (upper)
• Relay arm and connecting arm bolt
32 N·m (3.2 kgf·m, 24 lb·ft)
• Relay arm and swingarm bolt
T.
R.
(circumference and threaded portion) • Rear frame bolt (lower) “3”
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly lower bolt Rear frame bolt (lower)
29 N·m (2.9 kgf·m, 21 lb·ft)
Recommended lubricant
T.
R.
6. Install:
• Rear shock absorber assembly 2
1
TIP
• When installing the rear shock absorber as- 1 3
sembly, lift up the swingarm.
• Install the rear shock absorber assembly upper
bolt, and connecting arm bolt (frame side) from
the right. 3
• Install the rear shock absorber assembly lower 9. Tighten:
bolts, connecting arm bolt (relay arm side), and • Air filter case joint clamp “1”
relay arm bolt (swingarm side) from the left.
7. Tighten:
• Rear shock absorber assembly upper nut
Rear shock absorber assembly 1
upper nut
T.
• Connecting arm nut (relay arm side) 2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
T.
R.
4-59
SWINGARM
EAM20103
SWINGARM
Removing the swingarm
6
5 6
4 3
4 2
5
6
1
4-60
SWINGARM
EAM30071
• Bearing
REMOVING THE SWINGARM 4. Check:
1. Use a maintenance stand to raise the rear • Oil seal
wheel off the ground. Damage Replace.
EWA13120
WARNING • Bearing
• Thrust bearing
Securely support the vehicle so that there is
• Bushing
no danger of it falling over.
Free play exists/unsmooth revolution/rust
2. Measure: Replace bearing and bushing as a set.
• Swingarm side play
EAM30074
• Swingarm vertical movement INSTALLING THE SWINGARM
a. Measure the tightening torque of the pivot
1. Lubricate:
shaft nut.
• Bearing
Pivot shaft nut • Thrust bearing
85 N·m (8.5 kgf·m, 63 lb·ft) • Bushing
T.
• Collar
R.
TIP
First install the outer and then the inner bearings
to a specified depth from inside.
G088936
EAM30073 a a a a
CHECKING THE SWINGARM
1. Check: 2 New 2 New New 2
• Swingarm 1 1
Bends/cracks/damage Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface. 3 b b 3
Bends Replace.
EWA13770
WARNING 3. Install:
• Swingarm
Do not attempt to straighten a bent pivot
shaft. Pivot shaft nut
3. Wash with kerosene: 85 N·m (8.5 kgf·m, 63 lb·ft)
T.
R.
• Pivot shaft
TIP
• Bushing
Install the pivot shaft from the right.
• Collar
4-61
SWINGARM
4. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 4-7.
5. Adjust:
• Drive chain slack
Refer to “DRIVE CHAIN SLACK” on page
3-16.
Drive chain slack (Maintenance
Stand)
48.0–58.0 mm (1.89–2.28 in)
4-62
CHAIN DRIVE
EAM20104
CHAIN DRIVE
Removing the drive chain
4
3
5 N・m (0.5 kgf・m, 3.7 lb・ft)
4-63
CHAIN DRIVE
EAM30075
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Master link clip
• Master link “1” G088938
G089068
EAM30076
G088940
G088937
4. Check:
b. Calculate the length “c” of the 15-link sec-
• Drive chain roller “1”
tion of the drive chain using the following
Damage/wear Replace the drive chain.
formula.
• Drive chain side plate “2”
Drive chain 15-link section length “c” =
Damage/wear Replace the drive chain.
(length “a” between pin inner sides +
length “b” between pin outer sides)/2
4-64
CHAIN DRIVE
2 1
2
G088942 G089069
5. Lubricate:
• Drive chain
EAM30077
G088904 ECA14300
b. Correct NOTICE
Never install a new drive chain onto worn
1. Drive chain roller drive chain sprockets; this will dramatically
2. Drive sprocket shorten the drive chain’s life.
EAM30078
4. Adjust:
CHECKING THE REAR WHEEL SPROCKET • Drive chain slack
Refer to “CHECKING AND REPLACING THE Refer to “DRIVE CHAIN SLACK” on page
REAR WHEEL SPROCKET” on page 4-8. 3-16.
EAM30079
4-65
CHAIN DRIVE
4-66
ENGINE
2
REMOVING THE CYLINDER HEAD ..........................................................5-8
REMOVING THE PUSH ROD ....................................................................5-8
REMOVING THE PISTON..........................................................................5-8
CHECKING THE CYLINDER HEAD ..........................................................5-9
CHECKING THE CYLINDER AND PISTON...............................................5-9
3
COMBINATION OF PISTON AND CYLINDER ........................................5-10
CHECKING THE PISTON RING ..............................................................5-11
CHECKING THE PISTON PIN .................................................................5-11
CHECKING THE SMALL END BEARING ................................................5-12
CHECKING THE POWER VALVE ...........................................................5-12
CHECKING THE POWER VALVE HOLE ON CYLINDER .......................5-12
ASSEMBLING THE POWER VALVE .......................................................5-12
INSTALLING THE PISTON AND CYLINDER ..........................................5-13
4
INSTALLING THE CYLINDER HEAD ......................................................5-15
KICKSTARTER ...............................................................................................5-20
6
REMOVING THE PRIMARY DRIVE GEAR .............................................5-22
7
REMOVING THE KICK SHAFT ASSEMBLY ...........................................5-22
CHECKING THE KICK GEAR AND KICK IDLE GEAR ............................5-22
INSTALLING THE KICK SHAFT ASSEMBLY ..........................................5-22
INSTALLING THE KICK IDLE GEAR .......................................................5-23
INSTALLING THE PRIMARY DRIVE GEAR ............................................5-23
INSTALLING THE KICKSTARTER LEVER..............................................5-24
9
CHECKING THE GOVERNOR GROOVE ................................................5-26
CHECKING THE BEARING .....................................................................5-26
INSTALLING THE GOVERNOR...............................................................5-26
CLUTCH..........................................................................................................5-28
REMOVING THE CLUTCH ......................................................................5-30
CHECKING THE FRICTION PLATES ......................................................5-30
CHECKING THE CLUTCH PLATES ........................................................5-30
10
CHECKING THE CLUTCH SPRINGS ......................................................5-30
CHECKING THE CLUTCH HOUSING .....................................................5-30
CHECKING THE CLUTCH BOSS ............................................................5-30
CHECKING THE PRESSURE PLATE .....................................................5-31
CHECKING THE PUSH LEVER SHAFT ..................................................5-31
CHECKING THE PUSH RODS ................................................................5-31
CHECKING THE PRIMARY DRIVE GEAR ..............................................5-31
CHECKING THE PRIMARY DRIVEN GEAR............................................5-31
INSTALLING THE CLUTCH .....................................................................5-31
CRANKCASE .................................................................................................5-39
DISASSEMBLING THE CRANKCASE .....................................................5-40
CHECKING THE CRANKCASE ...............................................................5-40
ASSEMBLING THE CRANKCASE ...........................................................5-40
CRANKSHAFT ...............................................................................................5-43
REMOVING THE CRANKSHAFT.............................................................5-44
CHECKING THE CRANKSHAFT .............................................................5-44
INSTALLING THE CRANKSHAFT ...........................................................5-44
TRANSMISSION.............................................................................................5-46
REMOVING THE TRANSMISSION..........................................................5-47
CHECKING THE SHIFT FORKS ..............................................................5-47
CHECKING THE SHIFT DRUM ASSEMBLY ...........................................5-47
CHECKING THE TRANSMISSION ..........................................................5-47
INSTALLING THE TRANSMISSION ........................................................5-48
ENGINE REMOVAL
EAM20105
ENGINE REMOVAL
Removing the exhaust pipe
15 mm
12 N・m (1.2 kgf・m, 8.9 lb・ft) (0.59 in)
1
6 4
8
12 N・m (1.2 kgf・m, 8.9 lb・ft)
9
8
5-1
ENGINE REMOVAL
8 7
5 7
6
4
3
64 N・m (6.4 kgf・m, 47 lb・ft) 2
1
26 N・m (2.6 kgf・m, 19 lb・ft)
5-2
ENGINE REMOVAL
5-3
ENGINE REMOVAL
EAM30161
• Engine mounting nut (front side) “7”
REMOVING THE ENGINE
1. Remove: Engine mounting nut (front side)
• Pivot shaft “1” 64 N·m (6.4 kgf·m, 47 lb·ft)
T.
R.
TIP
If the pivot shaft is pulled all the way out, the • Engine bracket “8”
swingarm will come loose. If possible, insert a • Engine bracket bolt (upper side) “9”
shaft of similar diameter into the other side of the • Engine bracket nut (upper side) “10”
swingarm to support it. Engine bracket nut (upper side)
34 N·m (3.4 kgf·m, 25 lb·ft)
T.
R.
• Engine bracket bolt (lower side) “11”
• Engine bracket nut (lower side) “12”
Engine bracket nut (lower side)
34 N·m (3.4 kgf·m, 25 lb·ft)
T.
R.
TIP
Apply the molybdenum disulfide grease on the
pivot shaft.
2. Remove:
• Engine “1” M
(from right side) 9
TIP 11 8
Make sure that the couplers, hoses and cables
are disconnected.
2
1 8
10
7
EAM30164
3 12
INSTALLING THE ENGINE
1. Install: 6 4
• Engine “1”
(from the right side)
• Pivot shaft “2”
EAM30167
5-4
ENGINE REMOVAL
2 a
5-5
CYLINDER HEAD, CYLINDER AND PISTON
EAM20190
3
28 N・m (2.8 kgf・m, 21 lb・ft)
(3)
(4)
5 6
4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
5-6
CYLINDER HEAD, CYLINDER AND PISTON
5-7
CYLINDER HEAD, CYLINDER AND PISTON
EAM30086
EAM30543
2 1
2. Remove:
• Collar
EAM30544
5-8
CYLINDER HEAD, CYLINDER AND PISTON
Bore
54.000–54.014 mm (2.1260–
2. Check: 2.1265 in)
• Cylinder head Wear limit
Damage/scratches Replace. 54.064 mm (2.1285 in)
• Cylinder head water jacket
Mineral deposits/rust Eliminate. “C” = maximum of D1, D2, D3, D4, D5, D6
3. Measure:
• Cylinder head warpage
Out of specification Resurface the cylinder
head.
Warpage limit
0.03 mm (0.0012 in)
5-9
CYLINDER HEAD, CYLINDER AND PISTON
Diameter
53.957–53.972 mm (2.1243–
2.1249 in)
a
2. Check:
• Piston mark “a”
Piston mark “a”
Piston size
(color)
a. 17.5 mm (0.69 in) from the bottom edge of 53.957–53.960 mm
the piston A (red)
(2.1243–2.1244 in)
e. If out of specification, replace the piston 53.961–53.964 mm
B (orange) (2.1244–2.1246 in)
and piston rings as a set.
f. Calculate the piston-to-cylinder clearance 53.965–53.968 mm
C (green)
with the following formula. (2.1246–2.1247 in)
Piston-to-cylinder clearance = D (purple) 53.969–53.972 mm
Cylinder bore - Piston skirt diameter (2.1248–2.1249 in)
Piston-to-cylinder clearance
0.040–0.045 mm (0.0016–0.0018
in)
5-10
CYLINDER HEAD, CYLINDER AND PISTON
EAM30548 EAM30549
G089004
3. Measure:
• Piston pin bore inside diameter “b”
Out of specification Replace the piston.
G089002
Piston pin bore inside diameter
2. Install: limit
• Piston ring 15.040 mm (0.5921 in)
(into the cylinder)
TIP
Use the piston crown to level the piston ring near
bottom of cylinder “a”, where cylinder wear is
lowest.
3. Measure:
• Piston ring end gap
Out of specification Replace the piston
ring.
b
End gap limit G089005
G089003
b. Upper of cylinder
5-11
CYLINDER HEAD, CYLINDER AND PISTON
the aluminum.
Piston-pin-to-piston-pin-bore
clearance
0.008–0.023 mm (0.0003–0.0009
in)
Limit a a
0.065 mm (0.0026 in)
EAM30550
T.
R.
TIP
EAM30553 Install the power valve at cut-away faced “a” for
CHECKING THE POWER VALVE down side.
1. Check:
• Power valve 1, 2 “1”
Wear/damage Replace.
Carbon deposits Remove.
• Power valve holder “2” a
• Link lever “3”
• Valve shaft “4” 2
• Collar “5”
Wear/damage Replace.
1
• Spring “6”
3
Broken Replace.
2. Install:
1 • Link lever “1”
2 • Spring “2”
• Collar “3”
• Valve shaft “4”
• Power valve holder “5”
6 5 • Power valve link lever bolt “6”
3
6 Power valve link lever bolt
5
4 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
EAM30552 TIP
CHECKING THE POWER VALVE HOLE ON • Install the spring to the link lever, and then to
CYLINDER the cylinder.
1. Remove: • Install the spring with its stopper portion “a” fac-
• Carbon deposits ing inward.
(from the power valve hole surface “a”) • Apply the lithium-soap-based grease on the oil
TIP seal lip.
Do not use a sharp instrument. Avoid scratching
5-12
CYLINDER HEAD, CYLINDER AND PISTON
1
2
2 a
a
4 3 25 1 2 3 b
3
4
3. Install:
• Thrust plate “1” EAM30554
4. Check:
• Power valve smooth movement
Unsmooth movement Repair or replace.
5. Install:
• Gasket (power valve cover) “1” New
• Power valve cover “2” 2. Install:
• Power valve cover screw “3” • Cylinder gasket “1” New
Power valve cover screw • Small end bearing “2”
5 N·m (0.5 kgf·m, 3.7 lb·ft) (with the recommended lubricant)
• Dowel pin “3”
T.
R.
5-13
CYLINDER HEAD, CYLINDER AND PISTON
5. Install:
• Cylinder
• Cylinder nut “1”
Cylinder nut
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
3. Install:
• Piston “1”
• Piston pin “2”
• Piston pin clip “3” New
TIP
• Apply engine oil the piston pin.
• Make sure the mark “a” on the piston points to-
wards the exhaust side of the cylinder. TIP
• Before installing the piston pin clip, cover the • While compressing the piston ring with one
crankcase opening with a clean rag to prevent hand, install the cylinder with the other hand.
the clip from falling into the crankcase. • Tighten the nuts in stage, using a crisscross
• Do not allow the clip open ends to meet the pis- pattern.
ton pin slit “b”. 6. Install:
• Collar “1”
• Push rod “2”
a • Plain washer “3”
1
• Push rod bolt “4”
2 Push rod bolt
4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
T.
R.
ECA27100
NOTICE
3
Be sure to use the collar. If the collar is not
used, the power valve constituent parts will
result in damage.
TIP
• Insert the collar “5” included in owner’s tool kit
to install the push rod bolt.
• Do not forget to remove the collar.
4. Lubricate:
• Piston
• Piston ring
• Cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5-14
CYLINDER HEAD, CYLINDER AND PISTON
7. Remove:
3. Install:
• Collar
• Cylinder head “1”
8. Install:
• Copper washer “2” New
• Gasket (power valve housing) New
• Cylinder head nut “3”
• Power valve housing “1”
• Power valve housing bolt “2” Cylinder head nut
28 N·m (2.8 kgf·m, 21 lb·ft)
Power valve housing bolt
T.
R.
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
TIP
T.
R.
EAM30555
• Dowel pin
TIP
Apply the lithium-soap-based grease on the O-
rings.
5-15
CDI MAGNETO
EAM20191
CDI MAGNETO
Removing the CDI magneto
(3)
3
5-16
CDI MAGNETO
EAM30562
Damage Inspect the crankshaft runout and
REMOVING THE ROTOR crankshaft bearing.
1. Remove: If necessary, replace CDI magneto and/or
• Rotor nut “1” stator.
• Washer “2”
TIP
While holding the rotor with the rotor holding tool
“3”, loosen the rotor nut.
EAM30564
2. Remove:
• Rotor “1”
(with the flywheel puller “2”)
• Woodruff key
Flywheel puller
EAM30565
90890-01189
INSTALLING THE CDI MAGNETO
Flywheel puller
YM-01189 1. Install:
• Stator “1”
TIP • Stator coil screw “2”
When installing the flywheel puller, turn it coun- TIP
terclockwise. Temporarily tighten the screw at this point.
EAM30563 2. Install:
CHECKING THE CDI MAGNETO • Woodruff key “1”
1. Check: • Rotor “2”
• Rotor inner surface “a” TIP
• Stator outer surface “b” • Clean the tapered portions of the crankshaft
5-17
CDI MAGNETO
T.
• When installing the rotor, align the keyway “c”
R.
of the rotor with the woodruff key.
3
b
a
2
1
6. Check:
• Ignition timing
3. Install: Re-check the ignition timing.
• Washer “1” 7. Connect:
• Rotor nut “2” • CDI magneto lead “1”
(with the rotor holding tool “3”) Refer to “CABLE ROUTING DIAGRAM” on
page 2-15.
CDI magneto rotor nut
56 N·m (5.6 kgf·m, 41 lb·ft)
T.
R.
8. Install:
• Crankcase cover gasket (left) New
• Crankcase cover (left) “1”
• Crankcase cover screw (left) “2”
Crankcase cover screw (left)
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
TIP
4. Adjust: Tighten the screws in stage, using a crisscross
• Ignition timing pattern.
Refer to “CHECKING THE IGNITION TIM-
ING” on page 3-25.
5. Tighten:
• Stator coil screw “1”
TIP
• Mark “a” on the stator “2” should be aligned
with the ignition timing position mark “b” on the
crankcase “3”.
• Align the stator coil screws “1” with the center
5-18
CDI MAGNETO
5-19
KICKSTARTER
EAM20112
KICKSTARTER
Removing the primary drive gear
3
5
5-20
KICKSTARTER
5-21
KICKSTARTER
EAM30570
EAM30104
2. Install:
• Spring guide “1”
TIP
EAM30616
Slide the spring guide into the kick shaft, make
CHECKING THE KICK GEAR AND KICK IDLE sure the groove “a” in the spring guide fits on the
GEAR stopper of the torsion spring.
1. Check:
• Kick gear “1”
Wear/damage Replace the kick shaft as-
sembly.
• Kick idle gear “2”
• Gear teeth “a”
Wear/damage Replace.
3. Install:
• Kick shaft assembly “1”
TIP
• Apply the transmission oil on the kick shaft.
5-22
KICKSTARTER
• Slide the kick shaft assembly into the crank- • Primary drive gear “2”
case, make sure the clip “2” and kick shaft • Primary drive gear bolt “3”
stopper “a” fit into their home position “b”, “c”. TIP
Install the primary drive gear with its depressed
side toward you.
4. Hook:
• Torsion spring “1”
TIP 2. Install:
Turn the torsion spring clockwise and hook into • Primary driven gear
the proper hole “a” in the crankcase. Refer to “CLUTCH” on page 5-28.
3. Tighten:
• Primary drive gear bolt “1”
Primary drive gear bolt
48 N·m (4.8 kgf·m, 35 lb·ft)
T.
R.
TIP
Place an aluminum plate “a” between the teeth
of the primary drive gear and driven gear.
EAM30105
EAM30571
5-23
KICKSTARTER
5. Install:
• Crankcase cover (right) “1”
TIP
Mesh the governor gear “2”, and impeller shaft
gear “3” with primary drive gear “4”.
2. Install:
• Shift pedal “1”
• Shift pedal bolt “2”
Shift pedal bolt
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
6. Install:
R.
• Crankcase cover screw (right) “1” TIP
Align the upper line “a” of the shift pedal with the
Crankcase cover screw (right) center “b” of the crankcase projection and rotate
10 N·m (1.0 kgf·m, 7.4 lb·ft) the shift pedal counterclockwise until it first en-
T.
R.
EAM30572
TIP
Install the kickstarter closest to but not contact-
ing the pillar tube “4”.
5-24
YPVS GOVERNOR
EAM20192
YPVS GOVERNOR
Removing the YPVS governor
13
13
4
5
6
1 3 7
6
8
6
7
9
2 10
11
12
5-25
YPVS GOVERNOR
EAM30566 EAM30569
EAM30567
2
2
EAM30568 1
CHECKING THE BEARING
1. Check: 8
• Thrust bearing “1”
• Washer “2” 2. Install:
Wear/damage Replace. • Ball “1”
• Retainer “2”
(to the governor shaft “3”)
2 1 2 TIP
Apply the transmission oil on the retainer and
ball.
5-26
YPVS GOVERNOR
1 2
3. Install:
• Dowel pin “1”
TIP
• While compressing the spring, install the dowel
pin.
• Make sure the dowel pin fits into the groove “a”
in the retainer.
4. Install:
• Governor assembly “1”
TIP
Align the groove “a” in the governor with the fork
“b” and set the governor in the crankcase cover.
5-27
CLUTCH
EAM20111
CLUTCH
Removing the clutch
10 N・m (1.0 kgf・m, 7.4 lb・ft) 10 N・m (1.0 kgf・m, 7.4 lb・ft)
1
(5) 2
3
4
(5)
6
5
5-28
CLUTCH
23 1
80 N・m (8.0 kgf・m, 59 lb・ft)
4
17
7
8 16
15
10
11
12
13
14
5
6
Order Job/Parts to remove Q’ty Remarks
1 Push rod 1 1
2 Circlip 1
3 Washer 1
4 Bearing 1
5 Ball 1
6 Push rod 2 1
7 Clutch boss nut 1
8 Lock washer 1
9 Clutch boss 1
10 Thrust washer 1 [D = ø34 mm (1.34 in)]
11 Primary driven gear 1
12 Bearing 1
13 Spacer 1 1
14 Thrust washer 1 [D = ø34 mm (1.34 in)]
15 Push lever shaft 1
16 Oil seal 1
17 Bearing 1
5-29
CLUTCH
EAM30108
Out of specification Replace the clutch
REMOVING THE CLUTCH plates as a set.
1. Remove:
• Clutch boss nut “1” Thickness gauge
• Lock washer 90890-03268
• Clutch boss “2” Feeler gauge set
TIP YU-26900-9
• While holding the clutch boss with the clutch
holder “3”, loosen the clutch boss nut. Clutch plate thickness
• Do not use an impact wrench for removing the 1.50–1.70 mm (0.059–0.067 in)
clutch boss nut. Warpage limit
0.20 mm (0.008 in)
Clutch holder
90890-04199 EAM30111
EAM30110
5-30
CLUTCH
TIP 2. Measure:
Pitting on the clutch boss splines will cause er- • Push rod 2 bending limit
ratic clutch operation. Out of specification Replace.
Push rod bending limit
0.30 mm (0.012 in)
EAM30117
5-31
CLUTCH
4. Install:
• Lock washer “1” New
• Clutch boss nut “2”
Clutch boss nut
80 N·m (8.0 kgf·m, 59 lb·ft)
T.
R.
TIP
Use the clutch holder “3” to hold the clutch boss.
Clutch holder
90890-04199
Universal clutch holder
2 1
G YM-91042
G
3
2. Install:
• Thrust washer [D = ø34 mm (1.34 in)] “1”
• Spacer “2”
• Bearing “3”
• Primary driven gear “4” 5. Bend the lock washer “1” tab.
TIP
Apply the transmission oil on the bearing, spacer
and primary driven gear inner circumference.
6. Install:
• Friction plate “1”
• Clutch plate “2”
TIP
3. Install: • Install the clutch plates and friction plates alter-
• Thrust washer [D = ø34 mm (1.34 in)] “1” nately on the clutch boss, starting with a friction
• Clutch boss “2” plate and ending with a friction plate.
• Apply the transmission oil on the friction plates
and clutch plates.
5-32
CLUTCH
7. Install: 10.Install:
• Bearing “1” • Clutch spring
• Washer “2” • Clutch spring bolt
• Circlip “3” New
(to the push rod 1 “4”) Clutch spring bolt
TIP 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Apply the transmission oil on the bearing, wash-
er and push rod 1. TIP
Tighten the bolts in stage, using a crisscross pat-
tern.
G 11.Install:
• Dowel pin “1”
• Gasket (clutch cover) “2” New
3
2
1
4
8. Install:
• Push rod 2 “1”
• Ball “2”
• Push rod 1 “3”
TIP
Apply the transmission oil on the push rod 1, 2 12.Install:
and ball. • Clutch cover
• Clutch cover bolt
Clutch cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
Tighten the bolts in stage, using a crisscross pat-
tern.
13.Install:
• O-ring “1” New
• Clutch cable “2”
9. Install: TIP
• Pressure plate “1” • Insert the clutch cable “2” into the crankcase at
a straight angle so that it does not pinch the O-
ring “1”.
• Apply the lithium-soap-based grease on the O-
ring.
5-33
CLUTCH
5-34
SHIFT SHAFT
EAM20113
SHIFT SHAFT
Removing the shift shaft and stopper lever
2
3
5 6
7
12 N・m (1.2 kgf・m, 8.9 lb・ft)
5-35
SHIFT SHAFT
EAM30124
NOTICE
If the segment gets an impact, the stopper le-
EAM30127
ver may be damaged. Take care not to give
CHECKING THE STOPPER LEVER
an impact to it when removing the bolt.
1. Check:
• Stopper lever “1”
Wear/damage Replace.
• Roller “2”
Rotate outer race with a finger.
Rough spot/seizure Replace the stopper
lever.
• Torsion spring “3”
Broken Replace.
2
EAM30125
3
CHECKING THE SHIFT SHAFT
1. Check:
• Shift shaft “1”
Bends/damage/wear Replace. 1
• Shift shaft spring “2”
Damage/wear Replace.
EAM30131
LOCTITE®
R.
2. Check:
• Shift guide “1” • Washer “4”
• Shift lever “2” • Stopper lever “5”
• Pawl “3” • Stopper lever bolt “6”
• Pawl pin “4”
• Spring “5” Stopper lever bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
Wear/damage Replace.
T.
LOCTITE®
R.
TIP
Align the stopper lever roller with the slot on seg-
ment.
5-36
SHIFT SHAFT
2
LT
1 3
3 2
4
1
LT
5 G
6
2. Install: 4. Install:
• Segment “1” • Shift lever assembly
• Segment bolt (to the shift guide)
5. Install:
Segment • Shift lever assembly “1”
30 N·m (3.0 kgf·m, 22 lb·ft)
• Shift guide “2”
T.
R.
TIP TIP
• Align the notch “a” on the segment with the pin • The shift lever assembly is installed at the
“b” on the shift cam. same time as the shift guide.
• With the stopper lever pushed down, install the • Apply the transmission oil on the segment bolt
segment. shaft.
ECA24680
NOTICE
If the segment gets an impact, the stopper le-
ver may be damaged. Take care not to give
an impact to it when tightening the bolt.
6. Tighten:
• Shift guide bolt “1”
Shift guide bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
LOCTITE®
R.
3. Install:
• Spring “1”
• Pawl pin “2”
• Pawl “3”
LT
(to the shift lever)
TIP
Apply the transmission oil on the spring, pawl pin
and pawl.
1
7. Install:
• Roller “1”
• Shift shaft “2”
5-37
SHIFT SHAFT
TIP
Apply the transmission oil on the roller and shift
shaft.
8. Install:
• Shift pedal “1”
• Shift pedal bolt “2”
Shift pedal bolt
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
TIP
Align the upper line “a” of the shift pedal with the
center “b” of the crankcase projection and rotate
the shift pedal counterclockwise until it first en-
gages. Then install the shift pedal.
5-38
CRANKCASE
EAM20116
CRANKCASE
Separating the crankcase
6 2
2
9
4
2 2 2
10
10
5-39
CRANKCASE
EAM30147
TIP
• Make appropriate bolts “3” as shown available EAM30150
and carefully. Make sure the case halves ASSEMBLING THE CRANKCASE
separate evenly. If the cases do not separate, 1. Install:
check for a remaining case bolt or fitting. Do • Bearing “1” New
not force. (to the crankcase (left/right))
TIP
• Apply the engine oil on the bearing.
• Install the bearing by pressing its outer race
parallel.
2. Remove:
• Bearing “1”
TIP
• Remove the bearing from the crankcase by
pressing its inner race. 2. Install:
• Do not use the removed bearing. • Oil seal (left) “1” New
• Oil seal (right) “2” New
TIP
• Apply the lithium-soap-based grease on the oil
seal lip.
• Install the oil seal with its manufacture’s marks
or numbers facing outward.
5-40
CRANKCASE
3 M
4. Install: 2
1 a
• Dowel pin “1” 4 45–50 mm
• O-ring “2” New (1.77–1.97 in)
6
25–38 mm
(0.98–1.50 in)
5 4–5 mm
(0.16–0.20 in)
6. Install:
• Holder “1”
• Holder bolt “2”
Holder bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
LOCTITE®
R.
5. Install:
• Crankcase (right) “1”
Use the crankshaft installing tools “2”, “3”, “4”. TIP
Install the holder “1” so that the flat surface faces
to the right side of the vehicle.
5-41
CRANKCASE
LT
2
7. Install:
• Clamp “1”
• Crankcase bolt “2”
Crankcase bolt
14 N·m (1.4 kgf·m, 10 lb·ft)
T.
R.
TIP
Tighten the crankcase bolts in stage, using a
crisscross pattern.
1
2
5-42
CRANKSHAFT
EAM20193
CRANKSHAFT
Removing the crankshaft assembly
5-43
CRANKSHAFT
EAM30491
shaft.
REMOVING THE CRANKSHAFT
1. Remove: Crank assembly width
• Crankshaft “1” 55.90–55.95 mm (2.201–2.203 in)
(with the crankcase separating tool “2”)
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
TIP
Make appropriate bolts “3” as shown available
by yourself and attach the tool with them.
ECA22290
NOTICE
Do not use a hammer to drive out the crank- EAM30493
NOTICE
Runout limit
0.030 mm (0.0012 in) In order to prevent the crankshaft seizure,
apply molybdenum disulfide grease.
ECA23810
NOTICE
Do not use a hammer to drive in the crank-
a a shaft.
TIP
• Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of
the crankshaft installer bolt with the other. Turn
the crankshaft installer bolt until the crankshaft
assembly bottoms against the bearing.
2. Measure:
• Before installing the crankshaft, clean the con-
• Crank assembly width “a”
tacting surface of crankcase.
Out of specification Replace the crank-
• Apply the lithium-soap-based grease on the oil
5-44
CRANKSHAFT
seal lip.
1 M
4
2 3
5-45
TRANSMISSION
EAM20118
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
1
4
5
8
3
7
9
6
10 N・m (1.0 kgf・m, 7.4 lb・ft) 2
5-46
TRANSMISSION
EAM30153
2. Check:
• Shift fork movement
Unsmooth operation Replace shift fork.
TIP 2. Measure:
For a malfunctioning shift fork, replace not only • Drive axle runout
the shift fork itself but the two gears each adja- (with a centering device and dial gauge “1”)
cent to the shift fork. Out of specification Replace the drive axle.
Drive axle runout limit
0.01 mm (0.0004 in)
5-47
TRANSMISSION
TIP
• Apply the molybdenum disulfide oil on the in-
ner and end surface of the idler gear and on the
inner surface of the sliding gear, then install.
• Apply the molybdenum disulfide grease on the
inner surface of the 4th wheel gear, then install.
3. Check: 6 5
• Transmission gear
4
Blue discoloration/pitting/wear Replace
the defective gear(s). 3
• Transmission gear dog 2
Cracks/damage/rounded edges Replace
the defective gear(s).
4. Check:
• Transmission gear movement
Rough movement Replace the defective
gear(s). G
EAM30157
4
2. Install:
• 2nd wheel gear (29T) “1”
• 5th wheel gear (20T) “2”
• 3rd wheel gear (27T) “3”
• 4th wheel gear (23T) “4”
• 6th wheel gear (19T) “5”
• 1st wheel gear (31T) “6”
(to the drive axle “7”)
5-48
TRANSMISSION
6. Install:
• Shift cam “1”
TIP
• Apply the transmission oil on the shift cam.
• Install the shift cam while holding up the 5th
wheel gear “2” and keeping the shift fork 1 “3”
moved in the direction of the arrow.
4. Install:
• Collar “1”
TIP
• Apply the lithium-soap-based grease on the oil
seal lip.
• When installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.
7. Install:
• Guide bar (short) “1”
• Guide bar (long) “2”
TIP
1 • Apply the transmission oil on the guide bars.
• Be sure the long bar is inserted into the shift
forks 1 and 3 and the short one into 2.
5. Install:
• Shift fork 1 (L) “1” 2
• Shift fork 2 (C) “2” 1
• Shift fork 3 (R) “3”
TIP
• Apply the molybdenum disulfide oil on the shift
fork grooves. 8. Check:
• Mesh the shift fork 1 (L) with the 5th wheel gear • Shifter operation
“4” and the shift fork 3 (R) with the 6th wheel • Transmission operation
gear “6” on the drive axle. Unsmooth operation Repair.
• Mesh the shift fork 2 (C) with the 3rd/4th pinion
gear “5” on the main axle.
6
G 4
2
3
G
5
5-49
TRANSMISSION
5-50
COOLING SYSTEM
RADIATOR........................................................................................................6-2
CHECKING THE RADIATOR .....................................................................6-3
INSTALLING THE RADIATOR ...................................................................6-3
1
WATER PUMP ..................................................................................................6-5
DISASSEMBLING THE WATER PUMP .....................................................6-6
CHECKING THE WATER PUMP ...............................................................6-6
2
ASSEMBLING THE WATER PUMP ...........................................................6-6
3
4
5
6
7
8
9
10
COOLING SYSTEM DIAGRAMS
EAM20186
1. Radiator hose 1
2. Radiator (right)
3. Radiator hose 4
4. Water pump
5. Radiator (left)
6-1
RADIATOR
EAM20138
RADIATOR
Removing the radiator
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
9
6 3
7
2
1
8
2
5
6-2
RADIATOR
EAM30341
screwdriver. EAM30506
6-3
RADIATOR
G089031 1
4. Activate the tester to apply the test pressure.
Test pressure value
122.7 kPa (1.23 kgf/cm², 17.8 psi)
ECA24270
NOTICE
• Do not apply such a high pressure as ex-
ceeds the test pressure.
• Make sure that a checkup after the cylinder
head gasket is replaced is made after 3 min-
utes of warm-up.
• Make sure that coolant is filled up to the up-
per level beforehand.
5. Check:
• Pressure value
No stay for 5 to 10 seconds at the test pres-
sure value Correct.
• Radiator
• Radiator hose connections
Coolant leaks Correct or replace.
• Radiator hose
Bulges Replace.
EWA19090
WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.
6-4
WATER PUMP
EAM20139
WATER PUMP
Removing the water pump
(3)
1
6
4
5 2
3
7
6-5
WATER PUMP
EAM30494
EAM30259
TIP
• Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its position.
• When installing the impeller shaft, apply the
lithium-soap-based grease on the oil seal lip
and impeller shaft. And install the shaft while
turning it.
EAM30262
6-6
WATER PUMP
• Collar “4”
• Circlip “6” New
TIP
Install the impeller shaft gear with the dowel pin
fitted in the groove “a” in the same gear.
5. Install:
• Dowel pin “1”
• Gasket “2” New
6. Install:
• Water pump housing “1”
• Water pump housing cover bolt “2”
Water pump housing cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
6-7
FUEL SYSTEM
EAM20140
FUEL TANK
Removing the fuel tank
5 4
1
7 N・m (0.7 kgf・m, 5.2 lb・ft)
7-1
AIR FILTER
EAM20201
AIR FILTER
Removing the air filter element
2
3.5 N・m (0.35 kgf・m, 2.6 lb・ft) 1
3
4
8 N・m (0.8 kgf・m, 5.9 lb・ft)
5
6 (3)
(3)
a a
8 8
7
7-2
CARBURETOR
EAM20194
CARBURETOR
Removing the carburetor and reed valve
1
2
10 N・m (1.0 kgf・m, 7.4 lb・ft)
7-3
CARBURETOR
10
13
3
11 1
14
2
12 15
5
4
6
8
7
11
9
7-4
CARBURETOR
16
26 17
25
24 23
22 21
20
19
18
7-5
CARBURETOR
EAM30580
HANDLING NOTE
ECA27120
NOTICE
Do not loosen the screw (throttle position
sensor) “1” except when changing the throt-
tle position sensor due to failure because it
will cause a drop in engine performance.
6. Check:
• Needle valve “1”
• Needle valve seat “2”
Damage/wear “a” Replace.
1 1 Obstruction “b” Clean.
a 2
EAM30573
3. Check:
• Float chamber body
Dirt Clean.
4. Check:
• Float chamber rubber gasket
Cracks/damage/wear Replace.
5. Check:
• Float
Damage Replace.
7-6
CARBURETOR
a
a
2 3 4
EAM30577
8. Check: INSTALLING THE REED VALVE
• Free movement 1. Install:
Stick Repair or replace. • Gasket New
TIP • Reed valve assembly “1”
Insert the throttle valve “2” into the carburetor
body while pulling up the lever “1”, and check for
free movement.
2. Install:
• Carburetor joint “1”
• Carburetor joint bolt “2”
TIP
9. Check: Install the gasket so that the projection “a” is di-
• Hose joint rected as shown.
Cracks/damage Replace.
10.Check:
Carburetor joint bolt
• Air vent hose 10 N·m (1.0 kgf·m, 7.4 lb·ft)
• Fuel hose
T.
R.
Cracks/damage/wear Replace.
Obstruction Clean. 2
Blow out the hoses with compressed air.
1a
EAM30574
7-7
CARBURETOR
2. Install: 5. Install:
• Pilot jet “1” • O-ring
• Main jet “2” • Solenoid valve
(to the carburetor)
ECA27130
NOTICE
Before installing the solenoid valve, blow air
on the solenoid valve and its installing loca-
tion on the carburetor in order to remove any
foreign particles such as chips etc.
6. Install:
• Pilot air screw “1”
• Throttle stop screw “2”
3. Install: a. Turn in the pilot air screw until it is lightly
• Needle valve “1” seated.
• Float “2” b. Turn out the pilot air screw by the number
• Float pin “3” of turns recorded before removing.
TIP Air screw turns out
• After installing the needle valve to the float, in- 2-5/8
stall them to the carburetor.
• Check the float for smooth movement.
7. Install:
4. Install: • Starter plunger “1”
• Float chamber “1”
• Plate “2”
• Screw (float chamber) “3”
7-8
CARBURETOR
1 1 1 1
3 6
5
2
2 8 a
6
1 7
9. Install: b
• Jet needle “1”
11.Install:
• Collar “2”
• Mixing chamber top “1”
• Spring “3”
• Bolt (mixing chamber top) “2”
• Jet needle holder “4”
(to the carburetor “3”)
(to the throttle valve “5”)
TIP
• Insert the throttle valve into the carburetor body
while pulling up the lever “4”.
1 • After installing, check the throttle valve for
smooth movement.
5
4
2 3
10.Install:
• Throttle cable “1”
• Locknut “2”
Locknut (throttle cable carburetor
side)
T.
7-9
CARBURETOR
2
1
EAM30578 3. Tighten:
INSTALLING THE CARBURETOR • Carburetor joint bolt “1”
1. Install: TIP
• Carburetor “1” Place the bolt head “a” with its top as shown and
TIP secure the clamp in alignment with the horizon-
• Install the projection between the carburetor tal line “b” that passes the center of the carbure-
joint slot “a” as illustration. tor.
• Install the carburetor “1” so that the projection
does not get over the left side of the vehicle be-
yond the projection “b” of the carburetor joint.
1
b
a
1
4. Connect:
• Throttle position sensor lead
• Solenoid valve lead
Refer to “CABLE ROUTING DIAGRAM” on
a
b page 2-15.
5. Clamp:
• Air vent hose “1”
• Overflow hose “2”
2 Refer to “CABLE ROUTING DIAGRAM” on
page 2-15.
2. Carburetor joint 2
a. Slot
b. Projection
1
2. Tighten:
• Carburetor joint bolt “1”
6. Adjust:
• Idle speed
Refer to “CHECKING THE ENGINE IDLING
SPEED” on page 3-5.
7-10
CARBURETOR
EAM30579
7-11
ELECTRICAL SYSTEM
IGNITION SYSTEM...........................................................................................8-2
TROUBLESHOOTING................................................................................8-2
1
SOLENOID VALVE SYSTEM ...........................................................................8-3
TROUBLESHOOTING................................................................................8-3 2
THROTTLE POSITION SENSOR SYSTEM .....................................................8-4
TROUBLESHOOTING................................................................................8-4
ELECTRICAL COMPONENTS.........................................................................8-5
3
CHECKING THE SWITCHES.....................................................................8-6
4
CHECKING THE IGNITION SPARK GAP ..................................................8-8
CHECKING THE SPARK PLUG CAP ........................................................8-8
CHECKING THE IGNITION COIL ..............................................................8-8
CHECKING THE PICKUP COIL .................................................................8-9
CHECKING THE SOURCE COIL ...............................................................8-9
5
CHECKING THE SOLENOID VALVE OPERATION ................................8-10
CHECKING THE SOLENOID VALVE COIL .............................................8-10
HANDLING NOTE ....................................................................................8-11
CHECKING THE THROTTLE POSITION SENSOR COIL .......................8-11
CHANGING AND ADJUSTING THE THROTTLE POSITION
SENSOR..................................................................................................8-11
CHECKING THE THROTTLE POSITION SENSOR INPUT
VOLTAGE ................................................................................................8-13
6
7
8
9
10
WIRING DIAGRAM
EAM20195
WIRING DIAGRAM
R
B/W
B
B/W
L
B R
R
Y
L Y B/W B B B/W
B B/L
B R R
ON
Y L OFF
R
B/L
B
B
B
B
B
B
B
1. CDI unit
2. Engine stop switch
3. Ignition coil
4. Throttle position sensor
5. Solenoid valve
6. Joint connector
7. CDI magneto
8. Spark plug
EAM30608
COLOR CODE
B Black
L Blue
O Orange
R Red
Y Yellow
B/L Black/Blue
B/R Black/Red
B/W Black/White
G/L Green/Blue
G/W Green/White
W/L White/Blue
W/R White/Red
8-1
IGNITION SYSTEM
EAM20142
IGNITION SYSTEM
EAM30278
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Fuel tank
8-2
SOLENOID VALVE SYSTEM
EAM20196
TROUBLESHOOTING
If the solenoid valve will not operate, use the following inspection steps.
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Fuel tank
Use 12 V battery in this inspection.
8-3
THROTTLE POSITION SENSOR SYSTEM
EAM20197
TROUBLESHOOTING
If the throttle position sensor will not operate, use the following inspection steps.
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Fuel tank
8-4
ELECTRICAL COMPONENTS
EAM20147
ELECTRICAL COMPONENTS
1 2
1. CDI unit
2. Engine stop switch
3. Ignition coil
4. Throttle position sensor
5. Solenoid valve
8-5
ELECTRICAL COMPONENTS
EAM30289
8-6
ELECTRICAL COMPONENTS
Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
ECA14371
NOTICE
Never insert the tester probes into the coupler terminal slots. Always insert the probes from the
opposite end “a” of the coupler, taking care not to loosen or damage the leads.
TIP
When checking for continuity, switch back and forth between the switch positions a few times.
Terminal connections of the switch are shown in the terminal connection diagram below.
The switch positions “a” are shown in the far left column and the switch lead colors are shown in the
top row in the switch illustration.
TIP
“ ” indicates continuity between switch terminals (i.e., a closed circuit at each switch position).
The example illustration below shows that:
There is continuity between red and brown when the switch is “ON”.
8-7
ELECTRICAL COMPONENTS
EAM30294
TIP 2
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
1
a. Disconnect the spark plug cap from the
spark plug.
b. Connect the ignition checker “1” as
shown.
Ignition checker
90890-06754
Oppama pet–4000 spark checker b. Measure the spark plug cap resistance.
YM-34487 EAM30296
8-8
ELECTRICAL COMPONENTS
8-9
ELECTRICAL COMPONENTS
1 2
1
b. Measure the source coil resistance (B/R–
B).
3. Check: 2
• Charging coil 2 resistance
(G/L–G/W) 3. Check:
Out of specification Replace the CDI mag- • Solenoid valve “1”
neto. No click when connecting the battery Re-
Charging coil 2 resistance place.
44.0–66.0
Solenoid resistance
22.8–27.8
8-10
ELECTRICAL COMPONENTS
EAM30587
Out of specification Replace.
HANDLING NOTE
ECA27120 • Positive tester probe
NOTICE Yellow “1”
• Negative tester probe
Do not loosen the screw (throttle position Black “2”
sensor) “1” except when changing the throt-
tle position sensor due to failure because it
Throttle position sensor coil vari-
will cause a drop in engine performance.
able resistance
Full closed
0–2 k
Full opened
4–6 k
1 1
1 1
2
a
EAM30588
2
CHECKING THE THROTTLE POSITION
SENSOR COIL
1. Remove:
• Carburetor
• Mixing chamber top
Refer to “CARBURETOR” on page 7-3. 1
2. Check: 1
• Throttle position sensor coil resistance
Out of specification Replace. 2
8-11
ELECTRICAL COMPONENTS
3. Replace:
7. Insert the thin electric conductors “2” (lead
• Throttle position sensor
wire) into the throttle position sensor coupler
4. Install:
“1”, as shown, and connect the tester to them.
• Throttle position sensor “1”
• Throttle position sensor screw “2” • Positive tester probe
Yellow “3”
TIP • Negative tester probe
• Align the slot “a” in the throttle position sensor Black “4”
with the projection “b” on the carburetor while
the lever “c” is held down.
• Temporarily tighten the throttle position sensor 3
screw.
1
4 2
a b
c
2
1
2 8. Start the engine.
9. Adjust:
• Throttle position sensor output voltage
a. Adjust the installation angle of the throttle
5. Install: position sensor “1” to obtain the specified
• Mixing chamber top output voltage.
• Carburetor
Refer to “CARBURETOR” on page 7-3. Throttle position sensor output
6. Adjust: voltage
• Standard adjustment of engine idling speed 0.5–0.7 V
for throttle position sensor
a. Set the digital tachometer to the high ten-
sion cord.
1
b. Turn the throttle stop screw “1” until the
specified idle speed. 1
Refer to “CHECKING THE ENGINE
IDLING SPEED” on page 3-5.
Standard adjustment of engine
idling speed
1700–1900 r/min
10.Put the aligning marks “a” on the throttle po-
sition sensor and carburetor.
8-12
ELECTRICAL COMPONENTS
1
a
2
2
14.Install:
• Carburetor
Refer to “CARBURETOR” on page 7-3.
EAM30305
8-13
TROUBLESHOOTING
TROUBLESHOOTING ......................................................................................9-1
GENERAL INFORMATION ........................................................................9-1
TROUBLESHOOTING OF ENGINE ...........................................................9-1
TROUBLESHOOTING OF CLUTCH ..........................................................9-6
TROUBLESHOOTING OF TRANSMISSION .............................................9-7
1
TROUBLESHOOTING OF COOLING SYSTEM ........................................9-8
TROUBLESHOOTING OF BRAKE ............................................................9-9
TROUBLESHOOTING OF SUSPENSION .................................................9-9
TROUBLESHOOTING OF STEERING/HANDLING.................................9-11 2
3
4
5
6
7
8
9
10
TROUBLESHOOTING
EAM20148
TROUBLESHOOTING
EAM30309
GENERAL INFORMATION
TIP
Troubleshooting information provided here does not cover all the trouble symptoms, possible causes,
and remedial actions. Some items may not apply depending on the model. Use this information as a
guide and quick reference matrix when performing basic troubleshooting. Refer to the each chapter for
detailed information on checking, adjustment, and replacement.
EAM30612
TROUBLESHOOTING OF ENGINE
Engine will not start or is difficult to start, but it cranks.
Symptom Possible cause Actions
Spark plug does not produce a Refer to “TROUBLESHOOTING” under “IGNITION SYSTEM” on page
spark 8-2.
Empty fuel tank Fill the fuel tank with fuel.
Clogged fuel tank cap breather
Clean the fuel tank cap.
hole
Clean, repair, or replace the fuel
Clogged or damaged fuel hose
hose.
9-1
TROUBLESHOOTING
9-2
TROUBLESHOOTING
9-3
TROUBLESHOOTING
9-4
TROUBLESHOOTING
9-5
TROUBLESHOOTING
EAM30510
TROUBLESHOOTING OF CLUTCH
Manual clutch
Symptom Possible cause Actions
9-6
TROUBLESHOOTING
TROUBLESHOOTING OF TRANSMISSION
Symptom Possible cause Actions
Transmission noise Worn main axle spline Replace the main axle.
Worn drive axle spline Replace the drive axle.
Worn bearing Replace the bearing.
9-7
TROUBLESHOOTING
EAM30512
Carbon buildup in piston head and Clean the piston head and com-
combustion chamber bustion chamber.
Clogged engine cooling water Check and clean the engine cool-
passages ing water passages.
Damaged or leaking radiator Replace the radiator.
Faulty radiator cap Replace the radiator cap.
Clogged radiator fin Clean the radiator fin.
Repair the radiator fin or replace
Bent or damaged radiator fin
the radiator.
Damaged or faulty water pump Replace the water pump.
Overheating Damaged hoses or pipes Replace the hose or pipe.
Improperly connected hoses or Connect the hoses and pipes
pipes properly.
Clean or replace the air filter ele-
Clogged air filter element
ment.
Check the brake system and
Brake drags repair or replace faulty parts as
necessary.
Adjust to the specified spark plug
Incorrect spark plug gap
gap.
Incorrect spark plug heat range Replace the spark plug with the
one of the specified type.
Contact between the water pump Disassemble the water pump and
housing cover and impeller replace faulty parts.
Noise from water pump
Replace the water pump housing
Worn water pump housing bearing bearing.
9-8
TROUBLESHOOTING
EAM30513
TROUBLESHOOTING OF BRAKE
Symptom Possible cause Actions
EAM30514
TROUBLESHOOTING OF SUSPENSION
Symptom Possible cause Actions
9-9
TROUBLESHOOTING
9-10
TROUBLESHOOTING
TROUBLESHOOTING OF STEERING/HANDLING
Symptom Possible cause Actions
Handlebar wobble Warped front fork Repair or replace the front fork.
Bent front wheel axle Replace the front wheel axle.
Adjust to the specified tire pres-
Incorrect tire pressure
sure.
Worn, deformed, or incorrect tire Replace the tire.
Steering ring nut is tightened too Tighten the steering ring nut to the
tight. specified torque.
Bent lower bracket Replace the lower bracket.
Heavy steering Replace the bearing and bearing
Broken bearing or bearing race
race as a set.
Adjust to the specified tire pres-
Incorrect tire pressure
sure.
9-11
TROUBLESHOOTING
9-12
TROUBLESHOOTING
9-13
TUNING
ENGINE...........................................................................................................10-1
CARBURETOR SETTING ........................................................................10-1
ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS ..........10-1
TEST RUN ................................................................................................10-1
EFFECTS OF THE SETTING PARTS ON THE THROTTLE VALVE
1
OPENING ................................................................................................10-2
MAIN JET ADJUSTMENT ........................................................................10-2
ADJUSTING THE POWER JET ...............................................................10-2
PILOT AIR SCREW ADJUSTMENT .........................................................10-2
PILOT JET ADJUSTMENT .......................................................................10-3
2
JET NEEDLE ADJUSTMENT ...................................................................10-3
JET NEEDLE GROOVE POSITION ADJUSTMENT ................................10-4
RELATIONSHIP WITH THROTTLE OPENING........................................10-4
CARBURETOR SETTING PARTS ...........................................................10-5
ROAD CONDITION AND EXAMPLES OF CARBURETOR SETTING.....10-6
3
EXAMPLES OF CARBURETOR SETTING DEPENDING ON
4
SYMPTOM...............................................................................................10-6
CHANGE OF THE HEAT RANGE OF SPARK PLUGS............................10-8
CHASSIS ........................................................................................................10-9
SELECTION OF THE SECONDARY REDUCTION RATIO
(SPROCKET)...........................................................................................10-9
DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS.................10-9
TIRE PRESSURE .....................................................................................10-9
5
FRONT FORK SETTING ........................................................................10-10
6
CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL ........10-10
SETTING OF SPRING AFTER REPLACEMENT...................................10-10
FRONT FORK SETTING PARTS ...........................................................10-11
REAR SUSPENSION SETTING.............................................................10-11
CHOOSING SET LENGTH.....................................................................10-11
7
SETTING OF SPRING AFTER REPLACEMENT...................................10-12
REAR SHOCK ABSORBER SETTING PARTS .....................................10-12
SUSPENSION SETTING (FRONT FORK) .............................................10-14
SUSPENSION SETTING (REAR SHOCK ABSORBER)........................10-15
8
9
10
ENGINE
EAM20198
• Lower atmospheric pressure (at a high alti-
ENGINE tude) reduces the density of the air.
EAM30590 EAM30592
EAM30591
10-1
ENGINE
EAM30593
EAM30604
A. Closed
B. Full-open
10-2
ENGINE
EAM30596
NYFF
NYCF
NYDF
NYEF
EAM30597
10-3
ENGINE
EAM30605
10-4
ENGINE
EAM30599
Part name Size Part number Jet needle Rich NYFD B4X-14916-FD
10-5
ENGINE
EAM30601
15–25 C 15–25 C
Under 10 C (59–77 F) Over 25 C Under 10 C Over 25 C
(59–77 F)
(50 F) (Spring, (77 F) (50 F) (Spring, (77 F)
(Winter) (Summer) (Winter) (Summer)
Autumn) Autumn)
TIP
Optimum pilot air screw setting can be obtained by adding the ex-factory number of the same screw
back-out turns to any required value provided in the chart. For example, if the ex-factory number is “1”,
add “1” to the value chosen in the chart.
EAM30602
• At full throttle Increase main jet calibration no. • Discoloration of spark plug
Stall at high speeds (Gradually) If tan color, it is in good condition.
*Hard breathing • If cannot be corrected:
Shearing noise Clogged float valve seat
Whitish spark plug Clogged fuel hose
Clogged fuel cock
Lean mixture
• At full throttle Decrease main jet calibration no. • Discoloration of spark plug
Speed pick-up stops (Gradually) If tan color, it is in good condition.
Slow speed pick-up *In case of racing slight enrichment of • If cannot be corrected:
Slow response mixture reduces engine trouble. Clogged air filter
Sooty spark plug Fuel overflow from carburetor
Clogged main air passage or
Rich mixture clogged filter
10-6
ENGINE
* marked: In case of hard breathing, check the carburetor breather hoses for clogging.
This should be taken simply for an example. It is necessary to set the carburetor while checking the
operating conditions of the engine and discoloration of spark plugs.
Normally, carburetor setting is made by means of the main jet, jet needle clip position (including one
with 0.5 difference), pilot jet and pilot air screw. It the result of setting is still unsatisfactory, it is advisable
to change the diameter of the straight portion of the jet needle.
10-7
ENGINE
EAM30603
TIP
• When checking the discoloration of spark
plugs, be sure to stop the engine immediately
after a run and check.
• Avoid racing.
• When changing the heat range of spark plugs,
never attempt to change it more than ±1 rank.
• When using a spark plug other than standard,
check its heat range against the standard and
check that it is a resistance type.
• Note that even if the discoloration seems prop-
er, it may slightly vary with the spark plug mak-
er and oil in use.
10-8
CHASSIS
EAM20119
EAM30168
Rear wheel 47T 17D-25447-50
sprocket “2”
SELECTION OF THE SECONDARY 48T 17D-25448-50
REDUCTION RATIO (SPROCKET)
(STD) 49T B2W-25449-00
Secondary reduction ratio = Number of 50T B2W-25450-00
rear wheel sprocket teeth/Number of
drive sprocket teeth 51T B2W-25451-00
52T 17D-25452-50
Secondary reduction ratio
3.769 (49/13)
TIRE PRESSURE
machine can run at maximum speed, the ma-
Tire pressure should be adjusted to suit the road
chine is generally set such that it can develop
surface condition of the circuit.
its maximum revolutions toward the end of the
straight line, with care taken to avoid the en- Standard tire pressure
gine over-revving. 100 kPa (1.00 kgf/cm², 15 psi)
TIP
Riding technique varies from rider to rider and • Under a rainy, a muddy, a sandy, or a slippery
the performance of a machine also vary from condition, the tire pressure should be lower for
machine to machine. Therefore, do not imitate a larger area of contact with the road surface.
other rider’s settings from the beginning but
Extent of adjustment
choose your own setting according to the level of
60–80 kPa (0.60–0.80 kgf/cm², 9–
your riding technique. 12 psi)
EAM30169
• Under a stony or a hard road condition, the tire
DRIVE AND REAR WHEEL SPROCKETS
SETTING PARTS pressure should be higher to prevent a flat tire.
10-9
CHASSIS
EAM30171
10-10
CHASSIS
TIP
Generally a stiff spring gives a stiff riding feeling.
Rebound damping tends to become weaker, re-
sulting in lack of a sense of contact with the road
surface or in a vibrating handlebar.
EAM30174
10-11
CHASSIS
EAM30177
[Equal-pitch steel spring]
SETTING OF SPRING AFTER
REPLACEMENT STD spring rate
48
(N/mm)
After replacement, be sure to adjust the spring to
the set length [sunken length 90–100 mm (3.5– Spring
I.D.
3.9 in)] and set it. Type rate Part number
mark/Q’ty
(N/mm)
1. Use of soft spring
• Adjust to decrease rebound damping force to 5UN-22212-00
SOFT 42 Brown/1
compensate for less spring load. Run with the (Silver)
rebound damping force adjuster one or two 5UN-22212-10
44 Green/1
clicks turned out, and readjust it to suit your (Silver)
preference. 5UN-22212-20
46 Red/1
2. Use of stiff spring (Silver)
• Adjust to increase rebound damping force to 5UN-22212-30 *1
compensate for greater spring load. Run with (Silver)
the rebound damping force adjuster one or 48 Black/1
BCR-22212-00 *2
two clicks turned in, and readjust it to suit your (Blue)
preference.
5UN-22212-40 *1
TIP (Silver)
Adjusting the rebound damping force will be fol- 50 Blue/1
lowed more or less by a change in the compres- BCR-22212-10 *2
(Blue)
sion damping force. For correction, adjust to
decrease compression damping force. 5UN-22212-50 *1
(Silver)
EWA19200
52 Yellow/1
WARNING 5UN-22212-L0 *2
(Blue)
When using a rear shock absorber other
than currently installed, use the one whose 54
5UN-22212-60
Pink/1
overall length “a” does not exceed the stan- (Silver)
dard as it may result in faulty performance. 5UN-22212-70
STIFF 56 White/1
Never use one whose overall length is great- (Silver)
er than standard.
*1 B4X1
*2 B4X5
Length “a” of standard shock
[Unequal-pitch steel spring]
490 mm (19.29 in)
Spring
I.D.
Type rate Part number
mark/Q’ty
(N/mm)
5UN-22212-A0
SOFT 44 Green/2
(Silver)
5UN-22212-B0
46 Red/2
(Silver)
5UN-22212-C0
48 Black/2
(Silver)
5UN-22212-D0
50 Blue/2
(Silver)
EAM30178
5UN-22212-E0
REAR SHOCK ABSORBER SETTING PARTS 52 (Silver) Yellow/2
• Rear shock spring “1”
5UN-22212-F0
54 Pink/2
(Silver)
5UN-22212-G0
STIFF 56 White/2
(Silver)
10-12
CHASSIS
TIP
• The unequal-pitch spring is softer in initial char-
acteristic than the equal-pitch spring and is dif-
ficult to bottom out under full compression.
• The I.D. mark “a” is marked at the end of the
spring.
• Spring specification varies according to the
color and quantity of I.D. marks.
TIP
For the spring preload adjustment, refer to “AD-
JUSTING THE REAR SHOCK ABSORBER AS-
SEMBLY” on page 3-20.
10-13
CHASSIS
EAM30179
Section
Symptom Check Adjust
Large Medium Small
Jump
gap gap gap
10-14
CHASSIS
Section
Symptom Check Adjust
Large Medium Small
Jump gap gap gap
Section
Symptom Check Adjust
Large Medium Small
Jump
gap gap gap
10-15
CHASSIS
Section
Symptom Check Adjust
Large Medium Small
Jump
gap gap gap
10-16
CHASSIS
10-17
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Genuine Yamaha Parts text
EAM20160
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originally equipped on your vehicle, providing you with the performance and durability you have come
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